Absorbent article with a fluid-entangled body facing material including a plurality of hollow projections

ABSTRACT

An absorbent article having improved handling of body exudates can include a fluid-entangled body facing material including a support layer and a projection layer. The fluid-entangled body facing material can include a plurality of hollow projections formed from a first plurality of fibers in the projection layer. The hollow projections can extend from the outer surface of the projection layer in a direction away from the support layer. The absorbent article can minimize the amount of body exudates in contact with a wearer&#39;s skin and can minimize the incidence of leakage of body exudates from the absorbent article.

BACKGROUND

A primary function of personal care absorbent articles is to absorb andretain body exudates such as urine, fecal material, blood, and menseswith additional desired attributes including low leakage of the exudatesfrom the absorbent article and a dry feel to the wearer of the absorbentarticle. To accomplish these tasks, personal care absorbent articlesgenerally have an absorbent core and a cover enclosing the absorbentcore. The cover is usually fluid pervious on the body facing side of theabsorbent core and fluid impervious on the garment facing side of theabsorbent core. Absorbent articles commonly fail, however, to preventleakage of body exudates. Some body exudates, such as solid andsemi-solid fecal material and menses, have difficulty penetrating thebody facing material of the absorbent article as easily as low viscosityexudates, such as urine, and tend to spread across the surface of thebody facing material. Such spread of body exudates can result in leakageof the body exudates from the absorbent article.

Semi-solid fecal material, such as low viscosity fecal material whichcan be prevalent with younger children, and menses can be especiallydifficult to contain in an absorbent article. These exudates can movearound on the body facing material of an absorbent article under theinfluence of gravity, motion, and pressure by the wearer of theabsorbent article. The migration of the exudates is often towards theperimeter of the absorbent article, increasing the likelihood of leakageand smears against the skin of the wearer which can make clean-up of theskin difficult.

Attempts have been made in the past to provide body facing material toan absorbent article that can solve the problems described above. Onesuch approach has been the use of various types of embossing to createthree-dimensionality in the body facing surface of the absorbentarticle. This approach, however, requires high basis weight material tocreate a structure with significant topography. Furthermore, it isinherent in the embossing process that starting thickness of thematerial is lost due to the fact that embossing is, by its nature, acrushing and bonding process. Additionally, to “set” the embossments ina nonwoven fabric, the densified section is typically fused to createweld points that are typically impervious to the passage of bodyexudates. Hence, a part of the area for body exudates to transit throughthe material is lost. Also, “setting” the fabric can cause the materialto stiffen and become harsh to the touch.

Another approach has been to form fibrous webs on three-dimensionalforming surfaces. The resulting structures typically have littleresilience at low basis weights (assuming soft fibers with desirableaesthetic attributes are used) and the topography is significantlydegraded when wound on a roll and put through subsequent convertingprocesses. This is partly addressed in the three-dimensional formingprocess by allowing the three-dimensional shape to fill with fiber.This, however, typically comes at a higher cost due to the usage of morematerial. This also results in a loss of softness and the resultantmaterial becomes aesthetically unappealing for certain applications.

Another approach has been to aperture a fibrous web. Depending on theprocess, this can generate a flat two-dimensional web or a web with somethree-dimensionality where the displaced fiber is pushed out of theplane of the original web. Typically, the extent of thethree-dimensionality is limited and, under sufficient load, thedisplaced fiber may be pushed back toward its original positionresulting in at least partial closure of the aperture. Aperturingprocesses that attempt to “set” the displaced fiber outside the plane ofthe original web are also prone to degrading the softness of thestarting web. Another problem with apertured materials is that when theyare incorporated into end products such as with the use of adhesives,due to their open structure, the adhesives will often readily penetratethrough the apertures in the material from its underside to its top,exposed surface, thereby creating unwanted issues such as adhesivebuild-up in the converting process or creating unintended bonds betweenlayers within the finished product.

There remains a need for an absorbent article that can adequately reducethe incidence of leakage of body exudates from the absorbent article.There remains a need for an absorbent article which can provide improvedhandling of body exudates. There remains a need for an absorbent articlethat can minimize the amount of body exudates in contact with thewearer's skin. There remains a need for an absorbent article that canprovide physical and emotional comfort to the wearer of the absorbentarticle.

SUMMARY

In an embodiment, an absorbent article can have an outer cover, anabsorbent body, a body facing material, an acquisition layer positionedbetween the absorbent body and the body facing material, and a fluidtransfer layer positioned between the acquisition layer and theabsorbent body. In such an embodiment, the fluid transfer layer caninclude a polymeric material. In such an embodiment, the body facingmaterial can have a support layer and a projection layer. In such anembodiment, the projection layer can have an inner and an outer surfaceand can have a plurality of hollow projections extending from the outersurface of the projection layer. In various embodiments, the acquisitionlayer can have fibers with a denier greater than about 5. In variousembodiments, the body facing material of the absorbent article canfurther include a land area with greater than about 1% open area withina chosen area of the body facing material, projections having less thanabout 1% open area within a chosen area of the body facing material, aplurality of fibers of the projection layer entangled with the supportlayer, a load of more than about 2 Newtons per 25 mm width at 10%extension in the machine direction, projections having a height greaterthan about 1 mm, a resiliency of greater than about 70%, andcombinations thereof. In various embodiments, the absorbent body can befree from superabsorbent material. In various embodiments, the absorbentbody can have greater than about 15% superabsorbent material. In variousembodiments, the open area of the projections can be due to interstitialfiber-to-fiber spacing. In various embodiments, the open area of theland areas can be due to interstitial fiber-to-fiber spacing. In variousembodiments, the area of spread of fecal material simulant on the bodyfacing material following insult with fecal material simulant accordingto the test method described herein can be less than about 34 cm².

In an embodiment, an absorbent article can have an outer cover, anabsorbent body, a body facing material with a land area having greaterthan about 5% open area within a chosen area of the body facingmaterial, an acquisition layer positioned between the absorbent body andthe body facing material, and a fluid transfer layer positioned betweenthe acquisition layer and the absorbent body. In such an embodiment, thefluid transfer layer can contain a cellulosic material. In such anembodiment, the body facing material can have a support layer and aprojection layer. In such an embodiment, the projection layer can havean inner and an outer surface and can have a plurality of hollowprojections extending from the outer surface of the projection layerwherein the projections have less than about 1% open area within achosen area of the body facing material. In various embodiments, theacquisition layer can have fibers with a denier greater than about 5. Invarious embodiments, the acquisition layer can have fibers with a denierless than about 5. In various embodiments, the body facing material ofthe absorbent article can further include a plurality of fibers of theprojection layer entangled with the support layer, a load of more thanabout 2 Newtons per 25 mm width at 10% extension in the machinedirection, projections having a height greater than about 1 mm, aresiliency of greater than about 70%, and combinations thereof. Invarious embodiments, the absorbent body can be free from superabsorbentmaterial. In various embodiments, the absorbent body can have greaterthan about 15% superabsorbent material. In various embodiments, the openarea of the projections can be due to interstitial fiber-to-fiberspacing. In various embodiments, the open area of the land area can bedue to interstitial fiber-to-fiber spacing. In various embodiments, thearea of spread of fecal material simulant on the body facing materialfollowing insult with fecal material simulant according to the testmethod described herein can be less than about 34 cm².

In an embodiment, an absorbent article can have an outer cover, anabsorbent body, a body facing material, an acquisition layer positionedbetween the absorbent body and the body facing material, and a fluidtransfer layer positioned between the acquisition layer and theabsorbent body. In such an embodiment, the fluid transfer layer cancontain a cellulosic material. In such an embodiment, the body facingmaterial can have a support layer and a projection layer. In such anembodiment, the projection layer can have an inner and an outer surfaceand can have a plurality of hollow projections extending from the outersurface of the projection layer. In various embodiments, the acquisitionlayer can have fibers with a denier greater than about 5. In variousembodiments, the acquisition layer can have fibers with a denier lessthan about 5. In various embodiments, the body facing material of theabsorbent article can further include a plurality of fibers of theprojection layer entangled with the support layer, a load of more thanabout 2 Newtons per 25 mm width at 10% extension in the machinedirection, projections having a height greater than about 1 mm,projections having less than about 1% open area within a chosen area ofthe body facing material, a resiliency of greater than about 70%, andcombinations thereof. In various embodiments, the body facing materialcan have a land area and the land area can have an open area greaterthan about 1% within a chosen area of the body facing material. Invarious embodiments, the absorbent body can be free from superabsorbentmaterial. In various embodiments, the absorbent body can have greaterthan about 15% superabsorbent material. In various embodiments, the openarea of the projections is due to interstitial fiber-to-fiber spacing.In various embodiments, the open area of the land areas is due tointerstitial fiber-to-fiber spacing. In various embodiments, the area ofspread of fecal material simulant on the body facing material followinginsult with fecal material simulant according to the test methoddescribed herein can be less than about 34 cm².

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view illustration of an embodiment of an absorbentarticle.

FIG. 2 is a top down view of an embodiment of an absorbent article withportions cut away for clarity.

FIG. 3 is an exploded cross-sectional view of an embodiment of anabsorbent article.

FIG. 4 is an exploded cross-sectional view of another embodiment of anabsorbent article.

FIG. 5 is an exploded cross-sectional view of another embodiment of anabsorbent article.

FIG. 6 is an exploded cross-sectional view of another embodiment of anabsorbent article.

FIG. 7 is a perspective view of an embodiment of a body facing material.

FIG. 8 is a cross-sectional view of the body facing material of FIG. 7taken along line 8-8.

FIG. 9 is a cross-sectional view of the body facing material of FIG. 7taken along line 8-8 of FIG. 7 showing possible directions of fibermovements within the body facing material due to a fluid entanglementprocess.

FIG. 10 is a photomicrograph at a 45 degree angle showing a fluidentangled body facing material.

FIGS. 10A and 10B are photomicrographs showing a cross section of a bodyfacing material.

FIG. 11A is a top down view of an illustrative embodiment of aprojection layer of a body facing material in which two projections arepartially aligned with each other.

FIG. 11B is a top down view of an illustrative embodiment of aprojection layer of a body facing material in which two projections arecompletely aligned with each other.

FIG. 11C is a top down view of an illustrative embodiment of aprojection layer of a body facing material in which two projections arecompletely non-aligned with each other.

FIG. 12 is a schematic side view of an apparatus and a process forforming a fluid entangled body facing material.

FIG. 12A is an exploded view of a representative portion of a projectionforming surface.

FIG. 13 is a schematic side view of an alternate embodiment of anapparatus and a process for forming a fluid entangled body facingmaterial.

FIG. 14 is a schematic side view of an alternate embodiment of anapparatus and a process for forming a fluid entangled body facingmaterial. The apparatus and process illustrated in FIG. 14 is anadaptation of the apparatus and process illustrated in FIG. 13 as wellas subsequent FIGS. 15 and 17.

FIG. 15 is a schematic side view of an alternate embodiment of anapparatus and a process for forming a fluid entangled body facingmaterial.

FIG. 16 is a schematic side view of an alternate embodiment of anapparatus and a process for forming a fluid entangled body facingmaterial.

FIG. 17 is a schematic side view of an alternate embodiment of anapparatus and a process for forming a fluid entangled body facingmaterial.

FIG. 18 is a perspective view of an embodiment of an absorbent article.

FIG. 19 is a top down view of an embodiment of an absorbent article.

FIG. 20 is a perspective view of an exemplary illustration of a set-upof an imaging system used for determining the percent open area.

FIG. 21 is a perspective view of an exemplary illustration of a set-upof an imaging system used for determining projection height.

FIG. 22 is a graph depicting fabric thickness as a function of theoverfeed ratio of the projection layer into a forming process.

FIG. 23 is a graph depicting fabric extension at a 10N load as afunction of the overfeed ratio of the projection layer into the formingprocess for body facing materials and unsupported projections layers.

FIG. 24 is a graph depicting the load in Newtons per 50 mm width as afunction of the percent extension comparing both a body facing materialand an unsupported projection layer.

FIG. 25 is a graph depicting the load in Newtons per 50 mm width as afunction of the percent extension for a series of body facing materialswhile varying the overfeed ratio.

FIG. 26 is a graph depicting the load in Newtons per 50 mm width as afunction of the percent extension for a series of 45 gsm projectionlayers while varying the overfeed ratio.

FIG. 27 is a photomicrograph in top view of a sample designated as code3-6 in Table 1 of the specification.

FIG. 27A is a photomicrograph of a sample designated as code 3-6 inTable 1 of the specification taken at a 45 degree angle.

FIG. 28 is a photomicrograph in top view of a sample designated as code5-3 in Table 1 of the specification.

FIG. 28A is a photomicrograph of a sample designated as code 5-3 inTable 1 of the specification taken at a 45 degree angle.

FIG. 29 is a photomicrograph showing the juxtaposition of a portion of abody facing material with and without a support layer backing theprojection layer having been processed simultaneously on the sameapparatus.

FIG. 30 is a perspective view of an exemplary illustration of a set-upof a Digital Thickness Gauge.

FIG. 31 is a side view of an exemplary illustration of a set-up of aninjection apparatus.

FIG. 32 is a perspective view of an exemplary illustration of a set-upof the injection apparatus of FIG. 31.

FIG. 33 is a perspective view of an exemplary illustration of a set-upof an imaging system.

FIG. 34 is a top view of an exemplary illustration of a set-up of avacuum box.

FIG. 35 is a side view of the exemplary illustration of the vacuum boxof FIG. 34.

FIG. 36 is a rear view of the exemplary illustration of the vacuum boxof FIG. 34.

FIG. 37 is a graph depicting the area of spread of fecal materialsimulant on various absorbent composites.

FIG. 38 is a graph depicting the area of spread of fecal materialsimulant on various absorbent composites.

FIG. 39 is a graph depicting the area of spread of fecal materialsimulant on various absorbent composites.

FIG. 40 is a graph depicting the residual amount of fecal materialsimulant on various absorbent composites.

FIG. 41 is a graph depicting the residual amount of fecal materialsimulant on various absorbent composites.

FIG. 42 is a graph depicting the residual amount of fecal materialsimulant on various absorbent composites.

FIG. 43 is a graph depicting the residual amount of fecal materialsimulant on various absorbent composites.

FIG. 44 is a graph depicting the compressive stress versus thickness foran unsupported projection layer and two body facing materials under aone-cycle loading and unloading.

FIG. 45 is a graph depicting the load (N/25 mm) versus percent extensionfor an unsupported projection layer and two different body facingmaterials.

FIG. 46 is a top down view of an embodiment of a rate block.

FIG. 46A is a cross-sectional view of the rate block of FIG. 46.

DETAILED DESCRIPTION

In an embodiment, the present disclosure is generally directed towardsan absorbent article which can have improved management of bodyexudates. In an embodiment, the present disclosure is generally directedtowards an absorbent article having a body facing material which canhave hollow projections extending from a surface of the body facingmaterial. Without being bound by theory, it is believed that multipleattributes can be achieved by providing hollow projections to the bodyfacing material. First, by providing a body facing material with hollowprojections, the body facing material can have a higher degree ofthickness while minimizing the amount of material used. Increased bodyfacing material thickness can enhance the separation of the skin of thewearer from the absorbent body of an absorbent article, therebyimproving the prospect of drier skin. By providing projections, landareas can be created between the projections which can temporarilydistance body exudates from the high points of the projections while thebody exudates can be absorbed by the absorbent article. Providingprojections, therefore, can reduce skin contact with the body exudatesand provide better skin benefits. Secondly, by providing projections,the spread of the body exudates on the body facing material of theabsorbent article can be reduced thereby exposing less skin tocontamination. Thirdly, by reducing overall skin contact, a body facingmaterial with projections can provide a softer feel to the contactedskin thereby enhancing the tactile aesthetics of the body facingmaterial and the absorbent article. Fourthly, when materials withprojections are utilized as a body facing material for an absorbentarticle, the body facing material can also serve the function of actingas a cleaning aid when the absorbent article is removed from the wearer.

DEFINITIONS

The term “absorbent article” refers herein to an article which may beplaced against or in proximity to the body (i.e., contiguous with thebody) of the wearer to absorb and contain various liquid, solid, andsemi-solid exudates discharged from the body. Such absorbent articles,as described herein, are intended to be discarded after a limited periodof use instead of being laundered or otherwise restored for reuse. It isto be understood that the present disclosure is applicable to variousdisposable absorbent articles, including, but not limited to, diapers,training pants, youth pants, swim pants, feminine hygiene products,including, but not limited to, menstrual pads, incontinence products,medical garments, surgical pads and bandages, other personal care orhealth care garments, and the like without departing from the scope ofthe present disclosure.

The term “acquisition layer” refers herein to a layer capable ofaccepting and temporarily holding liquid body exudates to decelerate anddiffuse a surge or gush of the liquid body exudates and to subsequentlyrelease the liquid body exudates therefrom into another layer or layersof the absorbent article.

The term “bonded” refers herein to the joining, adhering, connecting,attaching, or the like, of two elements. Two elements will be consideredbonded together when they are joined, adhered, connected, attached, orthe like, directly to one another or indirectly to one another, such aswhen each is directly bonded to intermediate elements.

The term “carded web” refers herein to a web containing natural orsynthetic staple length fibers typically having fiber lengths less thanabout 100 mm. Bales of staple fibers can undergo an opening process toseparate the fibers which are then sent to a carding process whichseparates and combs the fibers to align them in the machine directionafter which the fibers are deposited onto a moving wire for furtherprocessing. Such webs are usually subjected to some type of bondingprocess such as thermal bonding using heat and/or pressure. In additionto or in lieu thereof, the fibers may be subject to adhesive processesto bind the fibers together such as by the use of powder adhesives. Thecarded web may be subjected to fluid entangling, such ashydroentangling, to further intertwine the fibers and thereby improvethe integrity of the carded web. Carded webs, due to the fiber alignmentin the machine direction, once bonded, will typically have more machinedirection strength than cross machine direction strength.

The term “film” refers herein to a thermoplastic film made using anextrusion and/or forming process, such as a cast film or blown filmextrusion process. The term includes apertured films, slit films, andother porous films which constitute liquid transfer films, as well asfilms which do not transfer fluids, such as, but not limited to, barrierfilms, filled films, breathable films, and oriented films.

The term “fluid entangling” and “fluid entangled” refers herein to aformation process for further increasing the degree of fiberentanglement within a given fibrous nonwoven web or between fibrousnonwoven webs and other materials so as to make the separation of theindividual fibers and/or the layers more difficult as a result of theentanglement. Generally this is accomplished by supporting the fibrousnonwoven web on some type of forming or carrier surface which has atleast some degree of permeability to the impinging pressurized fluid. Apressurized fluid stream (usually multiple streams) can then be directedagainst the surface of the nonwoven web which is opposite the supportedsurface of the web. The pressurized fluid contacts the fibers and forcesportions of the fibers in the direction of the fluid flow thusdisplacing all or a portion of a plurality of the fibers towards thesupported surface of the web. The result is a further entanglement ofthe fibers in what can be termed the Z-direction of the web (itsthickness) relative to its more planar dimension, its X-Y plane. Whentwo or more separate webs or other layers are placed adjacent oneanother on the forming/carrier surface and subjected to the pressurizedfluid, the generally desired result is that some of the fibers of atleast one of the webs are forced into the adjacent web or layer therebycausing fiber entanglement between the interfaces of the two surfaces soas to result in the bonding or joining of the webs/layers together dueto the increased entanglement of the fibers. The degree of bonding orentanglement will depend on a number of factors including, but notlimited to, the types of fibers being used, the fiber lengths, thedegree of pre-bonding or entanglement of the web or webs prior tosubjection to the fluid entangling process, the type of fluid being used(liquids, such as water, steam or gases, such as air), the pressure ofthe fluid, the number of fluid streams, the speed of the process, thedwell time of the fluid and the porosity of the web or webs/other layersand the forming/carrier surface. One of the most common fluid entanglingprocesses is referred to as hydroentangling which is a well-knownprocess to those of ordinary skill in the art of nonwoven webs. Examplesof fluid entangling process can be found in U.S. Pat. No. 4,939,016 toRadwanski et al., U.S. Pat. No. 3,485,706 to Evans, and U.S. Pat. Nos.4,970,104 and 4,959,531 to Radwanski, each of which is incorporatedherein in its entirety by reference thereto for all purposes.

The term “g/cc” refers herein to grams per cubic centimeter.

The term “gsm” refers herein to grams per square meter.

The term “hydrophilic” refers herein to fibers or the surfaces of fiberswhich are wetted by aqueous liquids in contact with the fibers. Thedegree of wetting of the materials can, in turn, be described in termsof the contact angles and the surface tensions of the liquids andmaterials involved. Equipment and techniques suitable for measuring thewettability of particular fiber materials or blends of fiber materialscan be provided by Cahn SFA-222 Surface Force Analyzer System, or asubstantially equivalent system. When measured with this system, fibershaving contact angles less than 90 are designated “wettable” orhydrophilic, and fibers having contact angles greater than 90 aredesignated “nonwettable” or hydrophobic.

The term “liquid impermeable” refers herein to a layer or multi-layerlaminate in which liquid body exudates, such as urine, will not passthrough the layer or laminate, under ordinary use conditions, in adirection generally perpendicular to the plane of the layer or laminateat the point of liquid contact.

The term “liquid permeable” refers herein to any material that is notliquid impermeable.

The term “meltblown” refers herein to fibers formed by extruding amolten thermoplastic material through a plurality of fine, usuallycircular, die capillaries as molten threads or filaments into converginghigh velocity heated gas (e.g., air) streams which attenuate thefilaments of molten thermoplastic material to reduce their diameter,which can be a microfiber diameter. Thereafter, the meltblown fibers arecarried by the high velocity gas stream and are deposited on acollecting surface to form a web of randomly dispersed meltblown fibers.Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 toButin et al., which is incorporated herein by reference. Meltblownfibers are microfibers which may be continuous or discontinuous, aregenerally smaller than about 0.6 denier, and may be tacky andself-bonding when deposited onto a collecting surface.

The term “nonwoven” refers herein to materials and webs of materialwhich are formed without the aid of a textile weaving or knittingprocess. The materials and webs of materials can have a structure ofindividual fibers, filaments, or threads (collectively referred to as“fibers”) which can be interlaid, but not in an identifiable manner asin a knitted fabric. Nonwoven materials or webs can be formed from manyprocesses such as, but not limited to, meltblowing processes,spunbonding processes, carded web processes, etc.

The term “pliable” refers herein to materials which are compliant andwhich will readily conform to the general shape and contours of thewearer's body.

The term “spunbond” refers herein to small diameter fibers which areformed by extruding molten thermoplastic material as filaments from aplurality of fine capillaries of a spinnerette having a circular orother configuration, with the diameter of the extruded filaments thenbeing rapidly reduced by a conventional process such as, for example,eductive drawing, and processes that described in U.S. Pat. No.4,340,563 to Appel et al., U.S. Pat. No. 3,692,618 to Dorschner et al.,U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartmann, U.S. Pat. No.3,502,538 to Peterson, and U.S. Pat. No. 3,542,615 to Dobo et al., eachof which is incorporated herein in its entirety by reference. Spunbondfibers are generally continuous and often have average deniers largerthan about 0.3, and in an embodiment, between about 0.6, 5 and 10 andabout 15, 20 and 40. Spunbond fibers are generally not tacky when theyare deposited on a collecting surface.

The term “superabsorbent” refers herein to a water-swellable,water-insoluble organic or inorganic material capable, under the mostfavorable conditions, of absorbing at least about 15 times its weightand, in an embodiment, at least about 30 times its weight, in an aqueoussolution containing 0.9 weight percent sodium chloride. Thesuperabsorbent materials can be natural, synthetic and modified naturalpolymers and materials. In addition, the superabsorbent materials can beinorganic materials, such as silica gels, or organic compounds, such ascross-linked polymers.

The term “thermoplastic” refers herein to a material which softens andwhich can be shaped when exposed to heat and which substantially returnsto a non-softened condition when cooled.

Absorbent Article:

Referring to FIG. 1, a disposable absorbent article 10 of the presentdisclosure is exemplified in the form of a diaper. It is to beunderstood that the present disclosure is suitable for use with variousother personal care absorbent articles, such as, for example, femininehygiene products, without departing from the scope of the presentdisclosure. While the embodiments and illustrations described herein maygenerally apply to absorbent articles manufactured in the productlongitudinal direction, which is hereinafter called the machinedirection manufacturing of a product, it should be noted that one ofordinary skill could apply the information herein to absorbent articlesmanufactured in the latitudinal direction of the product whichhereinafter is called the cross direction manufacturing of a productwithout departing from the spirit and scope of the disclosure. Theabsorbent article 10 illustrated in FIG. 1 includes a front waist region12, a back waist region 14, and a crotch region 16 interconnecting thefront and back waist regions, 12 and 14, respectively. The absorbentarticle 10 has a pair of longitudinal side edges, 18 and 20 (shown inFIG. 2), and a pair of opposite waist edges, respectively designatedfront waist edge 22 and back waist edge 24. The front waist region 12can be contiguous with the front waist edge 22 and the back waist region14 can be contiguous with the back waist edge 24.

Referring to FIG. 2, a non-limiting illustration of an absorbent article10, such as, for example, a diaper, is illustrated in a top down viewwith portions cut away for clarity of illustration. The absorbentarticle 10 can include an outer cover 26 and a body facing material 28.In an embodiment, the body facing material 28 can be bonded to the outercover 26 in a superposed relation by any suitable means such as, but notlimited to, adhesives, ultrasonic bonds, thermal bonds, pressure bonds,or other conventional techniques. The outer cover 26 can define alength, or longitudinal direction 30, and a width, or lateral direction32, which, in the illustrated embodiment, can coincide with the lengthand width of the absorbent article 10. The longitudinal direction 30 andthe lateral direction 32 of the absorbent article 10, and of thematerials which form the absorbent article 10, can provide the X-Yplanes, respectively, of the absorbent article 10 and of the materialswhich form the absorbent article 10. The absorbent article 10, and thematerials which form the absorbent article 10, can also have aZ-direction. A measurement, taken under pressure, in the Z-direction ofa material which forms the absorbent article 10 can provide ameasurement of the thickness of the material. A measurement, taken underpressure, in the Z-direction of the absorbent article 10 can provide ameasurement of the bulk of the absorbent article 10.

Referring to FIGS. 2-6, an absorbent body 40 can be disposed between theouter cover 26 and the body facing material 28. The absorbent body 40can have longitudinal edges, 42 and 44, which, in an embodiment, canform portions of the longitudinal side edges, 18 and 20, respectively,of the absorbent article 10 and can have opposite end edges, 46 and 48,which, in an embodiment, can form portions of the waist edges, 22 and24, respectively, of the absorbent article 10. In an embodiment, theabsorbent body 40 can have a length and width that are the same as orless than the length and width of the absorbent article 10. In anembodiment, a pair of containment flaps, 50 and 52, can be present andcan inhibit the lateral flow of body exudates.

The front waist region 12 can include the portion of the absorbentarticle 10 that, when worn, is positioned at least in part on the frontof the wearer while the back waist region 14 can include the portion ofthe absorbent article 10 that, when worn, is positioned at least in parton the back of the wearer. The crotch region 16 of the absorbent article10 can include the portion of the absorbent article 10, that, when worn,is positioned between the legs of the wearer and can partially cover thelower torso of the wearer. The waist edges, 22 and 24, of the absorbentarticle 10 are configured to encircle the waist of the wearer andtogether define the central waist opening 54 (such as shown in FIG. 1).Portions of the longitudinal side edges, 18 and 20, in the crotch region16 can generally define leg openings 56 (such as shown in FIG. 1) whenthe absorbent article 10 is worn.

The absorbent article 10 can be configured to contain and/or absorbliquid, solid, and semi-solid body exudates discharged from the wearer.For example, containment flaps, 50 and 52, can be configured to providea barrier to the lateral flow of body exudates. A flap elastic member,58 and 60, can be operatively joined to each containment flap, 50 and52, in any suitable manner known in the art. The elasticized containmentflaps, 50 and 52, can define a partially unattached edge that can assumean upright configuration in at least the crotch region 16 of theabsorbent article 10 to form a seal against the wearer's body. Thecontainment flaps, 50 and 52, can be located along the absorbent article10 longitudinal side edges, 18 and 20, and can extend longitudinallyalong the entire length of absorbent article 10 or can extend partiallyalong the length of the absorbent article 10. Suitable construction andarrangements for containment flaps, 50 and 52, are generally well knownto those skilled in the art and are described in U.S. Pat. No. 4,704,116issued Nov. 3, 1987, to Enloe and U.S. Pat. No. 5,562,650 issued Oct. 8,1996 to Everett et al., which are incorporated herein by reference.

In various embodiments, the absorbent article 10 can include a secondaryliner 34 (such as exemplified in FIG. 4 and FIG. 6). In suchembodiments, the secondary liner 34 can have a body facing surface 36and a garment facing surface 38. In such embodiments, the body facingmaterial 28 can be bonded to the body facing surface 36 of the secondaryliner 34.

To further enhance containment and/or absorption of body exudates, theabsorbent article 10 can suitably include a front waist elastic member62, a rear waist elastic member 64, and leg elastic members, 66 and 68,as are known to those skilled in the art. The waist elastic members, 62and 64, can be attached to the outer cover 26, the body facing material28, and/or the secondary liner 34 along the opposite waist edges, 22 and24, and can extend over part or all of the waist edges, 22 and 24. Theleg elastic members, 66 and 68, can be attached to the outer cover 26,the body facing material 28, and/or the secondary liner 34 along theopposite longitudinal side edges, 18 and 20, and positioned in thecrotch region 16 of the absorbent article 10.

In various embodiments, the body facing material 28 of an absorbentarticle 10 can have a load of more than about 2 Newtons per 25 mm widthat a 10% extension in the machine direction as measured using the LoadVersus Percent Extension test method described herein. In variousembodiments, the body facing material 28 can have projections which havea height greater than about 1 mm as measured using the Method toDetermine Height of Projections test method described herein. In variousembodiments, the body facing material 28 of an absorbent article 10 canhave a resiliency of greater than about 70% as measured using thePercent Resiliency—One Cycle Compression test method described herein.In various embodiments, the amount of residual fecal material simulanton the body facing material 28 of an absorbent article 10 followinginsult with fecal material simulant can be less than about 2.5 grams asmeasured using the Determination of Residual Fecal Material Simulanttest method described herein. In various embodiments, the area of spreadof fecal material simulant on the body facing material 28 of anabsorbent article 10 following insult with fecal material simulant canbe less than about 34 cm² as measured using the Determination of Area ofSpread of Fecal Material Simulant test method described herein. Invarious embodiments, the body facing material 28 can have projections 90which have less than about 1% open area in a chosen area of the bodyfacing material 28 as measured using the Method to Determine PercentOpen Area test method described herein. In various embodiments, the bodyfacing material 28 can have a land area 116 which can have greater thanabout 1% open area in a chosen area of the body facing material 28 asmeasured using the Method to Determine Percent Open Area test methoddescribed herein. In various embodiments, the intake time for a secondintake through a body facing material 28 on an absorbent article 10following insult with a menses simulant can be less than commerciallyavailable absorbent articles as measured using the Intake/Rewet testmethod described herein. In various embodiments, the intake time for asecond intake through a body facing material 28 on an absorbent article10 can be from about 25 or 30% to about 50, 60 or 70% less thancommercially available products following insult with a menses simulantas measured using the Intake/Rewet test method described herein. Invarious embodiments, the intake time for a second intake through a bodyfacing material 28 on an absorbent article 10 can be less than about 30seconds following insult of a menses simulant as measured using theIntake/Rewet test method described herein. In various embodiments, thebody facing material 28 can have a land area 116 with a percent openarea greater than the percent open area of a projection 90 as measuredaccording to the Method to Determine Percent Open Area test methoddescribed herein.

Additional details regarding each of these elements of the absorbentarticle 10 described herein can be found below and with reference to theFigures.

Outer Cover:

The outer cover 26 can be breathable and/or liquid impermeable. Theouter cover 26 can be elastic, stretchable or non-stretchable. The outercover 26 may be constructed of a single layer, multiple layers,laminates, spunbond fabrics, films, meltblown fabrics, elastic netting,microporous webs, bonded-carded webs or foams provided by elastomeric orpolymeric materials. In an embodiment, for example, the outer cover 26can be constructed of a microporous polymeric film, such as polyethyleneor polypropylene.

In an embodiment, the outer cover 26 can be a single layer of a liquidimpermeable material. In an embodiment, the outer cover 26 can besuitably stretchable, and more suitably elastic, in at least the lateralor circumferential direction 32 of the absorbent article 10. In anembodiment, the outer cover 26 can be stretchable, and more suitablyelastic, in both the lateral 32 and the longitudinal 30 directions. Inan embodiment, the outer cover 26 can be a multi-layered laminate inwhich at least one of the layers is liquid impermeable. In an embodimentsuch as illustrated in FIGS. 3-6, the outer cover 26 may be a two layerconstruction, including an outer layer 70 material and an inner layer 72material which can be bonded together such as by a laminate adhesive.Suitable laminate adhesives can be applied continuously orintermittently as beads, a spray, parallel swirls, or the like. Suitableadhesives can be obtained from Bostik Findlay Adhesives, Inc. ofWauwatosa, Wis., U.S.A. It is to be understood that the inner layer 72can be bonded to the outer layer 70 utilizing ultrasonic bonds, thermalbonds, pressure bonds, or the like.

The outer layer 70 of the outer cover 26 can be any suitable materialand may be one that provides a generally cloth-like texture orappearance to the wearer. An example of such material can be a 100%polypropylene bonded-carded web with a diamond bond pattern availablefrom Sandler A.G., Germany, such as 30 gsm Sawabond 4185® or equivalent.Another example of material suitable for use as an outer layer 70 of anouter cover 26 can be a 20 gsm spunbond polypropylene non-woven web. Theouter layer 70 may also be constructed of the same materials from whichthe secondary liner 34 can be constructed as described herein.

The liquid impermeable inner layer 72 of the outer cover 26 (or theliquid impermeable outer cover 26 where the outer cover 26 is of asingle-layer construction) can be either vapor permeable (i.e.,“breathable”) or vapor impermeable. The liquid impermeable inner layer72 (or the liquid impermeable outer cover 26 where the outer cover 26 isof a single-layer construction) may be manufactured from a thin plasticfilm, although other liquid impermeable materials may also be used. Theliquid impermeable inner layer 72 (or the liquid impermeable outer cover26 where the outer cover 26 is of a single-layer construction) caninhibit liquid body exudates from leaking out of the absorbent article10 and wetting articles, such as bed sheets and clothing, as well as thewearer and caregiver. An example of a material for a liquid impermeableinner layer 72 (or the liquid impermeable outer cover 26 where the outercover 26 is of a single-layer construction) can be a printed 19 gsmBerry Plastics XP-8695H film or equivalent commercially available fromBerry Plastics Corporation, Evansville, Ind., U.S.A.

Where the outer cover 26 is of a single layer construction, it can beembossed and/or matte finished to provide a more cloth-like texture orappearance. The outer cover 26 can permit vapors to escape from theabsorbent article 10 while preventing liquids from passing through. Asuitable liquid impermeable, vapor permeable material can be composed ofa microporous polymer film or a non-woven material which has been coatedor otherwise treated to impart a desired level of liquid impermeability.

Absorbent Body:

The absorbent body 40 can be suitably constructed to be generallycompressible, conformable, pliable, non-irritating to the wearer's skinand capable of absorbing and retaining liquid body exudates. Theabsorbent body 40 can be manufactured in a wide variety of sizes andshapes (for example, rectangular, trapezoidal, T-shape, 1-shape,hourglass shape, etc.) and from a wide variety of materials. The sizeand the absorbent capacity of the absorbent body 40 should be compatiblewith the size of the intended wearer and the liquid loading imparted bythe intended use of the absorbent article 10. Additionally, the size andthe absorbent capacity of the absorbent body 40 can be varied toaccommodate wearers ranging from infants to adults.

The absorbent body 40 may have a length ranging from about 150, 160,170, 180, 190, 200, 210, 220, 225, 230, 240, 250, 260, 270, 280, 290,300, 310, 320, 330, 340, or 350 mm to about 355, 360, 380, 385, 390,395, 400, 410, 415, 420, 425, 440, 450, 460, 480, 500, 510, or 520 mm.The absorbent body 40 may have a crotch width ranging from about 30, 40,50, 55, 60, 65, or 70 mm to about 75, 80, 85, 90, 95, 100, 105, 110,115, 120, 125, 130, 140, 150, 160, 170 or 180 mm. The width of theabsorbent body 40 located within the front waist region 12 and/or theback waist region 14 of the absorbent article 10 may range from about50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 mm to about 100, 105, 110,115, 120, 125 or 130 mm. As noted herein, the absorbent body 40 can havea length and width that can be less than or equal to the length andwidth of the absorbent article 10.

In an embodiment, the absorbent article 10 can be a diaper having thefollowing ranges of lengths and widths of an absorbent body 40 having anhourglass shape: the length of the absorbent body 40 may range fromabout 170, 180, 190, 200, 210, 220, 225, 240 or 250 mm to about 260,280, 300, 310, 320, 330, 340, 350, 355, 360, 380, 385, or 390 mm; thewidth of the absorbent body 40 in the crotch region 16 may range fromabout 40, 50, 55, or 60 mm to about 65, 70, 75, or 80 mm; the width ofthe absorbent body 40 in the front waist region 12 and/or the back waistregion 14 may range from about 80, 85, 90, or 95 mm to about 100, 105,or 110 mm.

In an embodiment, the absorbent article 10 may be a training pant oryouth pant having the following ranges of lengths and widths of anabsorbent body 40 having an hourglass shape: the length of the absorbentbody 40 may range from about 400, 410, 420, 440 or 450 mm to about 460,480, 500, 510 or 520 mm; the width of the absorbent body 40 in thecrotch region 16 may range from about 50, 55, or 60 mm to about 65, 70,75, or 80 mm; the width of the absorbent body 40 in the front waistregion 12 and/or the back waist region 14 may range from about 80, 85,90, or 95 mm to about 100, 105, 110, 115, 120, 125, or 130 mm.

In an embodiment, the absorbent article 10 can be an adult incontinencegarment having the following ranges of lengths and widths of anabsorbent body 40 having a rectangular shape: the length of theabsorbent body 40 may range from about 400, 410 or 415 to about 425 or450 mm; the width of the absorbent body 40 in the crotch region 16 mayrange from about 90, or 95 mm to about 100, 105, or 110 mm. It should benoted that the absorbent body 40 of an adult incontinence garment may ormay not extend into either or both the front waist region 12 or the backwaist region 14 of the absorbent article 10.

In an embodiment, the absorbent article 10 can be a feminine hygieneproduct having the following ranges of lengths and widths of anabsorbent body 40 having an hourglass shape: the length of the absorbentbody 40 may range from about 150, 160, 170, or 180 mm to about 190, 200,210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310 or 320 mm; thewidth of the absorbent body in the crotch region 16 may range from about30, 40, or 50 mm to about 60, 70, 80, 90 or 100 mm.

The absorbent body 40 can have two surfaces, 74 and 76, such as a wearerfacing surface 74 and a garment facing surface 76. Edges, such aslongitudinal side edges, 42 and 44, and such as front and back endedges, 46 and 48, can connect the two surfaces, 74 and 76.

In an embodiment, the absorbent body 40 can be composed of a webmaterial of hydrophilic fibers, cellulosic fibers (e.g., wood pulpfibers), natural fibers, synthetic fibers, woven or nonwoven sheets,scrim netting or other stabilizing structures, superabsorbent material,binder materials, surfactants, selected hydrophobic and hydrophilicmaterials, pigments, lotions, odor control agents or the like, as wellas combinations thereof. In an embodiment, the absorbent body 40 can bea matrix of cellulosic fluff and superabsorbent material.

In an embodiment, the absorbent body 40 may be constructed of a singlelayer of materials, or in the alternative, may be constructed of twolayers of materials or more. In an embodiment in which the absorbentbody 40 has two layers, the absorbent body 40 can have a wearer facinglayer suitably composed of hydrophilic fibers and a garment facing layersuitably composed at least in part of a high absorbency materialcommonly known as superabsorbent material. In such an embodiment, thewearer facing layer of the absorbent body 40 can be suitably composed ofcellulosic fluff, such as wood pulp fluff, and the garment facing layerof the absorbent body 40 can be suitably composed of superabsorbentmaterial, or a mixture of cellulosic fluff and superabsorbent material.As a result, the wearer facing layer can have a lower absorbent capacityper unit weight than the garment facing layer. The wearer facing layermay alternatively be composed of a mixture of hydrophilic fibers andsuperabsorbent material, as long as the concentration of superabsorbentmaterial present in the wearer facing layer is lower than theconcentration of superabsorbent material present in the garment facinglayer so that the wearer facing layer can have a lower absorbentcapacity per unit weight than the garment facing layer. It is alsocontemplated that the garment facing layer may be composed solely ofsuperabsorbent material without departing from the scope of thisdisclosure. It is also contemplated that, in an embodiment, each of thelayers, the wearer facing and garment facing layers, can have asuperabsorbent material such that the absorbent capacities of the twosuperabsorbent materials can be different and can provide the absorbentbody 40 with a lower absorbent capacity in the wearer facing layer thanin the garment facing layer.

Various types of wettable, hydrophilic fibers can be used in theabsorbent body 40. Examples of suitable fibers include natural fibers,cellulosic fibers, synthetic fibers composed of cellulose or cellulosederivatives, such as rayon fibers; inorganic fibers composed of aninherently wettable material, such as glass fibers; synthetic fibersmade from inherently wettable thermoplastic polymers, such as particularpolyester or polyamide fibers, or composed of nonwettable thermoplasticpolymers, such as polyolefin fibers which have been hydrophilized bysuitable means. The fibers may be hydrophilized, for example, bytreatment with a surfactant, treatment with silica, treatment with amaterial which has a suitable hydrophilic moiety and is not readilyremoved from the fiber, or by sheathing the nonwettable, hydrophobicfiber with a hydrophilic polymer during or after formation of the fiber.For example, one suitable type of fiber is a wood pulp that is ableached, highly absorbent sulfate wood pulp containing primarily softwood fibers. However, the wood pulp can be exchanged with other fibermaterials, such as synthetic, polymeric, or meltblown fibers or with acombination of meltblown and natural fibers. In an embodiment, thecellulosic fluff can include a blend of wood pulp fluff. An example ofwood pulp fluff can be “CoosAbsorb™ S Fluff Pulp” or equivalentavailable from Abitibi Bowater, Greenville, S.C., U.S.A., which is ableached, highly absorbent sulfate wood pulp containing primarilysouthern soft wood fibers.

The absorbent body 40 can be formed with a dry-forming technique, anair-forming technique, a wet-forming technique, a foam-formingtechnique, or the like, as well as combinations thereof. A coformnonwoven material may also be employed. Methods and apparatus forcarrying out such techniques are well known in the art.

Suitable superabsorbent materials can be selected from natural,synthetic, and modified natural polymers and materials. Thesuperabsorbent materials can be inorganic materials, such as silicagels, or organic compounds, such as cross-linked polymers. Cross-linkingmay be covalent, ionic, Van der Waals, or hydrogen bonding. Typically, asuperabsorbent material can be capable of absorbing at least about tentimes its weight in liquid. In an embodiment, the superabsorbentmaterial can absorb more than twenty-four times its weight in liquid.Examples of superabsorbent materials include polyacrylamides, polyvinylalcohol, ethylene maleic anhydride copolymers, polyvinyl ethers,hydroxypropyl cellulose, carboxymal methyl cellulose,polyvinylmorpholinone, polymers and copolymers of vinyl sulfonic acid,polyacrylates, polyacrylamides, polyvinyl pyrrolidone, and the like.Additional polymers suitable for superabsorbent material includehydrolyzed, acrylonitrile grafted starch, acrylic acid grafted starch,polyacrylates and isobutylene maleic anhydride copolymers and mixturesthereof. The superabsorbent material may be in the form of discreteparticles. The discrete particles can be of any desired shape, forexample, spiral or semi-spiral, cubic, rod-like, polyhedral, etc. Shapeshaving a largest greatest dimension/smallest dimension ratio, such asneedles, flakes, and fibers are also contemplated for use herein.Conglomerates of particles of superabsorbent materials may also be usedin the absorbent body 40.

In an embodiment, the absorbent body 40 can be free of superabsorbentmaterial. In an embodiment, the absorbent body 40 can have at leastabout 15% by weight of a superabsorbent material. In an embodiment, theabsorbent body 40 can have at least about 15, 20, 25, 30, 35, 40, 45,50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 99 or 100% by weight of asuperabsorbent material. In an embodiment, the absorbent body 40 canhave less than about 100, 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50,45, 40 35, 30, 25, or 20% by weight of a superabsorbent material. In anembodiment, the absorbent body 40 can have from about 15, 20, 25, 30,35, 40, 45, 50, 55 or 60% to about 65, 70, 75, 80, 85, 90, 95, 99 or100% by weight of a superabsorbent material. Examples of superabsorbentmaterial include, but are not limited to, FAVOR SXM-9300 or equivalentavailable from Evonik Industries, Greensboro, N.C., U.S.A. and HYSORB8760 or equivalent available from BASF Corporation, Charlotte, N.C.,U.S.A.

The absorbent body 40 can be superposed over the inner layer 72 of theouter cover 26, extending laterally between the leg elastic members, 66and 68, and can be bonded to the inner layer 72 of the outer cover 26,such as by being bonded thereto with adhesive. However, it is to beunderstood that the absorbent body 40 may be in contact with, and notbonded with, the outer cover 26 and remain within the scope of thisdisclosure. In an embodiment, the outer cover 26 can be composed of asingle layer and the absorbent body 40 can be in contact with the singerlayer of the outer cover 26. In an embodiment, a layer, such as but notlimited to, a fluid transfer layer 78, can be positioned between theabsorbent body 40 and the outer cover 26.

Fluid Transfer Layer:

In various embodiments, such as illustrated in the non-limiting exampleof FIG. 3, an absorbent article 10 can be constructed without a fluidtransfer layer 78. In various embodiments, such as illustrated in thenon-limiting examples of FIGS. 4-6, the absorbent article 10 can have afluid transfer layer 78. The fluid transfer layer 78 can have a wearerfacing surface 80 and a garment facing surface 82. In an embodiment, thefluid transfer layer 78 can be in contact with the absorbent body 40. Inan embodiment, the fluid transfer layer 78 can be bonded to theabsorbent body 40. Bonding of the fluid transfer layer 78 to theabsorbent body 40 can occur via any means known to one of ordinaryskill, such as, but not limited to, adhesives. In an embodiment, such asillustrated in the non-limiting example of FIG. 4, a fluid transferlayer 78 can be positioned between the body facing material 28 and theabsorbent core 40. In an embodiment, such as illustrated in thenon-limiting example of FIG. 5, a fluid transfer layer 78 can completelyencompass the absorbent body 40 and can be sealed to itself. In such anembodiment, the fluid transfer layer 78 may be folded over on itself andthen sealed using, for example, heat and/or pressure. In an embodiment,such as, for example, in the non-limiting illustration of FIG. 6, afluid transfer layer 78 may be composed of separate sheets of materialwhich can be utilized to partially or fully encompass the absorbent body40 and which can be sealed together using a sealing means such as anultrasonic bonder or other thermochemical bonding means or the use of anadhesive.

In an embodiment, the fluid transfer layer 78 can be in contact withand/or bonded with the wearer facing surface 74 of the absorbent body40. In an embodiment, the fluid transfer layer 78 can be in contact withand/or bonded with the wearer facing surface 74 and at least one of theedges, 42, 44, 46 and/or 48, of the absorbent body 40. In an embodiment,the fluid transfer layer 78 can be in contact with and/or bonded withthe wearer facing surface 74, at least one of the edges, 42, 44, 46and/or 48, and the garment facing surface 76 of the absorbent body 40.In an embodiment, the absorbent body 40 may be partially or completelyencompassed by a fluid transfer layer 78.

The fluid transfer layer 78 can be pliable, less hydrophilic than theabsorbent body 40, and sufficiently porous to thereby permit liquid bodyexudates to penetrate through the fluid transfer layer 78 to reach theabsorbent body 40. In an embodiment, the fluid transfer layer 78 canhave sufficient structural integrity to withstand wetting thereof and ofthe absorbent body 40. In an embodiment, the fluid transfer layer 78 canbe constructed from a single layer of material or it may be a laminateconstructed from two or more layers of material.

In an embodiment, the fluid transfer layer 78 can include, but is notlimited to, natural and synthetic fibers such as, but not limited to,polyester, polypropylene, acetate, nylon, polymeric materials,cellulosic materials such as wood pulp, cotton, rayon, viscose, LYOCELL®such as from Lenzing Company of Austria, or mixtures of these or othercellulosic fibers, and combinations thereof. Natural fibers can include,but are not limited to, wool, cotton, flax, hemp, and wood pulp. Woodpulps can include, but are not limited to, standard softwood fluffinggrade such as “CoosAbsorb™ S Fluff Pulp” or equivalent available fromAbitibi Bowater, Greenville, S.C., U.S.A., which is a bleached, highlyabsorbent sulfate wood pulp containing primarily southern soft woodfibers.

In various embodiments, the fluid transfer layer 78 can includecellulosic material. In various embodiments, the fluid transfer layer 78can be creped wadding or a high-strength tissue. In various embodiments,the fluid transfer layer 78 can include polymeric material. In anembodiment, a fluid transfer layer 78 can include a spunbond material.In an embodiment, a fluid transfer layer 78 can include a meltblownmaterial. In an embodiment, the fluid transfer layer 78 can be alaminate of a meltblown nonwoven material having fine fibers laminatedto at least one spunbond nonwoven material layer having coarse fibers.In such an embodiment, the fluid transfer layer 78 can be aspunbond-meltblown (“SM”) material. In an embodiment, the fluid transferlayer 78 can be a spunbond-meltblown-spunbond (“SMS”) material. Anon-limiting example of such a fluid transfer layer 78 can be a 10 gsmspunbond-meltblown-spunbond material. In various embodiments, the fluidtransfer layer 78 can be composed of at least one material which hasbeen hydraulically entangled into a nonwoven substrate. In variousembodiments, the fluid transfer layer 78 can be composed of at least twomaterials which have been hydraulically entangled into a nonwovensubstrate. In various embodiments, the fluid transfer layer 78 can haveat least three materials which have been hydraulically entangled into anonwoven substrate. A non-limiting example of a fluid transfer layer 78can be a 33 gsm hydraulically entangled substrate. In such an example,the fluid transfer layer 78 can be a 33 gsm hydraulically entangledsubstrate composed of a 12 gsm spunbond material, a 10 gsm wood pulpmaterial having a length from about 0.6 cm to about 5.5 cm, and an 11gsm polyester staple fiber material. To manufacture the fluid transferlayer 78 just described, the 12 gsm spunbond material can provide a baselayer while the 10 gsm wood pulp material and the 11 gsm polyesterstaple fiber material can be homogeneously mixed together and depositedonto the spunbond material and then hydraulically entangled with thespunbond material.

In various embodiments, a wet strength agent can be included in thefluid transfer layer 78. A non-limiting example of a wet strength agentcan be Kymene 6500 (557LK) or equivalent available from Ashland Inc. ofAshland, Ky., U.S.A. In various embodiments, a surfactant can beincluded in the fluid transfer layer 78. In various embodiments, thefluid transfer layer 78 can be hydrophilic. In various embodiments, thefluid transfer layer 78 can be hydrophobic and can be treated in anymanner known in the art to be made hydrophilic.

In an embodiment, the fluid transfer layer 78 can be in contact withand/or bonded with an absorbent body 40 which is made at least partiallyof particulate material such as superabsorbent material. In anembodiment in which the fluid transfer layer 78 at least partially orcompletely encompasses the absorbent body 40, the fluid transfer layer78 should not unduly expand or stretch as this might cause theparticulate material to escape from the absorbent body 40. In anembodiment, the fluid transfer layer 78, while in a dry state, shouldhave respective extension values at peak load in the machine and crossdirections of 30 percent or less and 40 percent or less, respectively.

In an embodiment, the fluid transfer layer 78 may have a longitudinallength the same as, greater than, or less than the longitudinal lengthof the absorbent body 40. The fluid transfer layer 78 can have alongitudinal length ranging from about 150, 160, 170, 180, 190, 200,210, 220, 225, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330,340, or 350 mm to about 355, 360, 380, 385, 390, 395, 400, 410, 415,420, 425, 440, 450, 460, 480, 500, 510, or 520 mm.

Acquisition Layer:

In various embodiments, such as illustrated, for example, in FIG. 5, theabsorbent article 10 can have an acquisition layer 84. The acquisitionlayer 84 can help decelerate and diffuse surges or gushes of liquid bodyexudates penetrating the body facing material 28. In an embodiment, theacquisition layer 84 can be positioned between the body facing material28 and the absorbent body 40 to take in and distribute body exudates forabsorption by the absorbent body 40. In an embodiment, the acquisitionlayer 84 can be positioned between the body facing material 28 and afluid transfer layer 78 if a fluid transfer layer 78 is present. In anembodiment, the acquisition layer 84 can be positioned between asecondary liner 34, if present, and the absorbent body 40.

The acquisition layer 84 can have a wearer facing surface 86 and agarment facing surface 88. In an embodiment, the acquisition layer 84can be in contact with and/or bonded with the body facing material 28.In an embodiment in which the acquisition layer 84 is bonded with thebody facing material 28, bonding of the acquisition layer 84 to the bodyfacing material 28 can occur through the use of an adhesive and/or pointfusion bonding. The point fusion bonding can be selected from, but isnot limited to, ultrasonic bonding, pressure bonding, thermal bonding,and combinations thereof. In an embodiment, the point fusion bonding canbe provided in any pattern as deemed suitable.

The acquisition layer 84 may have any longitudinal length dimension asdeemed suitable. The acquisition layer 84 may have a longitudinal lengthfrom about 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 225,230, 240, or 250 mm to about 260, 270, 280, 290, 300, 310, 320, 340,350, 360, 380, 400, 410, 415, 420, 425, 440, 450, 460, 480, 500, 510 or520 mm. In an embodiment, the acquisition layer 84 can have any lengthsuch that the acquisition layer 84 can be coterminous with the waistedges, 22 and 24, of the absorbent article 10.

In an embodiment, the longitudinal length of the acquisition layer 84can be the same as the longitudinal length of the absorbent body 40. Insuch an embodiment the midpoint of the longitudinal length of theacquisition layer 84 can substantially align with the midpoint of thelongitudinal length of the absorbent body 40.

In an embodiment, the longitudinal length of the acquisition layer 84can be shorter than the longitudinal length of the absorbent body 40. Insuch an embodiment, the acquisition layer 84 may be positioned at anydesired location along the longitudinal length of the absorbent body 40.As an example of such an embodiment, the absorbent article 10 maycontain a target area where repeated liquid surges typically occur inthe absorbent article 10. The particular location of a target area canvary depending on the age and gender of the wearer of the absorbentarticle 10. For example, males tend to urinate further toward the frontregion of the absorbent article 10 and the target area may be phasedforward within the absorbent article 10. For example, the target areafor a male wearer may be positioned about 2¾″ forward of thelongitudinal midpoint of the absorbent body 40 and may have a length ofabout ±3″ and a width of about ±2″. The female target area can belocated closer to the center of the crotch region 16 of the absorbentarticle 10. For example, the target area for a female wearer may bepositioned about 1″ forward of the longitudinal midpoint of theabsorbent body 40 and may have a length of about ±3″ and a width ofabout ±2″. As a result, the relative longitudinal placement of theacquisition layer 84 within the absorbent article 10 can be selected tobest correspond with the target area of either or both categories ofwearers.

In an embodiment, the absorbent article 10 may contain a target areacentered within the crotch region 16 of the absorbent article 10 withthe premise that the absorbent article 10 would be worn by a femalewearer. The acquisition layer 84, therefore, may be positioned along thelongitudinal length of the absorbent article 10 such that theacquisition layer 84 can be substantially aligned with the target areaof the absorbent article 10 intended for a female wearer. Alternatively,the absorbent article 10 may contain a target area positioned betweenthe crotch region 16 and the front waist region 12 of the absorbentarticle 10 with the premise that the absorbent article 10 would be wornby a male wearer. The acquisition layer 84, therefore, may be positionedalong the longitudinal length of the absorbent article 10 such that theacquisition layer 84 can be substantially aligned with the target areaof the absorbent article 10 intended for a male wearer.

In an embodiment, the acquisition layer 84 can have a size dimensionthat is the same size dimension as the target area of the absorbentarticle 10 or a size dimension greater than the size dimension of thetarget area of the absorbent article 10. In an embodiment, theacquisition layer 84 can be in contact with and/or bonded with the bodyfacing material 28 at least partially in the target area of theabsorbent article 10.

In various embodiments, the acquisition layer 84 can have a longitudinallength shorter than, the same as or longer than the longitudinal lengthof the absorbent body 40. In an embodiment in which the absorbentarticle 10 is a diaper, the acquisition layer 84 may have a longitudinallength from about 120, 130, 140, 150, 160, 170, or 180 mm to about 200,210, 220, 225, 240, 260, 280, 300, 310 or 320 mm. In such an embodiment,the acquisition layer 84 may be shorter in longitudinal length than thelongitudinal length of the absorbent body 40 and may be phased from thefront end edge 46 of the absorbent body 40 a distance of from about 15,20, or 25 mm to about 30, 35 or 40 mm. In an embodiment in which theabsorbent article 10 may be a training pant or youth pant, theacquisition layer 84 may have a longitudinal length from about 120, 130,140, 150, 200, 210, 220, 230, 240 or 250 mm to about 260, 270, 280, 290,300, 340, 360, 400, 410, 420, 440, 450, 460, 480, 500, 510 or 520 mm. Insuch an embodiment, the acquisition layer 84 may have a longitudinallength shorter than the longitudinal length of the absorbent body 40 andmay be phased a distance of from about 25, 30, 35 or 40 mm to about 45,50, 55, 60, 65, 70, 75, 80 or 85 mm from the front end edge 46 of theabsorbent body 40. In an embodiment in which the absorbent article 10 isan adult incontinence garment, the acquisition layer 84 may have alongitudinal length from about 200, 210, 220, 230, 240, or 250 mm toabout 260, 270, 280, 290, 300, 320, 340, 360, 380, 400, 410, 415, 425,or 450 mm. In such an embodiment, the acquisition layer 84 may have alongitudinal length shorter than the longitudinal length of theabsorbent body 40 and the acquisition layer 84 may be phased a distanceof from about 20, 25, 30 or 35 mm to about 40, 45, 50, 55, 60, 65, 70 or75 mm from the front end edge 46 of the absorbent body 40.

The acquisition layer 84 may have any width as desired. The acquisitionlayer 84 may have a width dimension from about 15, 20, 25, 30, 35, 40,45, 50, 55, 60, or 70 mm to about 80, 90, 100, 110, 115, 120, 130, 140,150, 160, 170, or 180 mm. The width of the acquisition layer 84 may varydependent upon the size and shape of the absorbent article 10 withinwhich the acquisition layer 84 will be placed. The acquisition layer 84can have a width smaller than, the same as, or larger than the width ofthe absorbent body 40. Within the crotch region 16 of the absorbentarticle 10, the acquisition layer 84 can have a width smaller than, thesame as, or larger than the width of the absorbent body 40.

In an embodiment, the acquisition layer 84 can include natural fibers,synthetic fibers, superabsorbent material, woven material, nonwovenmaterial, wet-laid fibrous webs, a substantially unbounded airlaidfibrous web, an operatively bonded, stabilized-airlaid fibrous web, orthe like, as well as combinations thereof. In an embodiment, theacquisition layer 84 can be formed from a material that is substantiallyhydrophobic, such as a nonwoven web composed of polypropylene,polyethylene, polyester, and the like, and combinations thereof.

In various embodiments, the acquisition layer 84 can have fibers whichcan have a denier of greater than about 5. In various embodiments, theacquisition layer 84 can have fibers which can have a denier of lessthan about 5.

In an embodiment, the acquisition layer 84 can be a through-airbonded-carded web such as a 50 gsm through-air bonded-carded webcomposite having a homogenous blend of about 50% sheath/core bicomponentpolyethylene/polypropylene fibers having a fiber diameter of 3 denierand about 50% sheath/core bicomponent polyethylene/polypropylene fibershaving a fiber diameter of 1.5 denier. An example of such a composite isa composite having about 50% ES FiberVisions 3 denier ESC-233bicomponent fibers and about 50% ES FiberVisions 1.5 denier ESC-215bicomponent fibers, or equivalent composite, available from ESFiberVisions Corp., Duluth, Ga., U.S.A.

In an embodiment, the acquisition layer 84 can be a through-airbonded-carded web such as a 50 gsm through-air bonded-carded webcomposite having a homogenous blend of about 50% Rayon fibers having afiber diameter of 3 denier and about 50% sheath/core bicomponentpolyethylene/polypropylene fibers having a fiber diameter of 1.5 denier.An example of such a composite is a composite having about 50% Kelheim 3denier Rayon Galaxy fibers and about 50% ES FiberVisions 1.5 denierESC-215 bicomponent fibers, or equivalent composite, available from ESFiberVisions Corp., Duluth, Ga., U.S.A.

In an embodiment, the acquisition layer 84 can be a through-airbonded-carded web such as a 50 gsm through-air bonded-carded webcomposite having a homogenous blend of about 40% hollow polypropylenefibers having a fiber diameter of 7 denier and about 60% sheath/corebicomponent polyethylene/polypropylene fibers having a fiber diameter of17 denier. An example of such a composite is a composite having about40% ES FiberVisions 7 denier T-118 hollow polypropylene fibers and about60% ES FiberVisions 17 denier Varde bicomponent fibers, or equivalentcomposite, available from ES FiberVisions Corp., Duluth, Ga., U.S.A.

In an embodiment, the acquisition layer 84 can be a through-airbonded-carded web such as a 35 gsm through-air bonded-carded webcomposite having a homogenous mixture of about 35% sheath/corebicomponent polyethylene/polypropylene fibers having a fiber diameter of6 denier, about 35% sheath/core bicomponent polyethylene/polypropylenefibers having a fiber diameter of 2 denier, and about 30% polyesterfibers having a fiber diameter of 6 denier. An example of such acomposite is a composite having about 35% Huvis 180-N (PE/PP 6d), about35% Huvis N-215 (PE/PP 2d), and about 30% Huvis SD-10 PET 6d, orequivalent composite, available from SamBo Company, Ltd, Korea.

In an embodiment, the acquisition layer 84 can be a thermally bonded,stabilized-airlaid fibrous web (e.g. Concert product codeDT200.100.D0001) which is available from Glatfelter, a business havingoffices located in York, Pa., U.S.A.

In an embodiment, the acquisition layer 84 can include a coform/foammaterial. In an embodiment, the acquisition layer 84 can include aresilient coform material. As used herein, the term “coform” refers to ablend of meltblown fibers and absorbent fibers such as cellulosic fibersthat can be formed by air forming a meltblown polymer material whilesimultaneously blowing air-suspended fibers into the stream of meltblownfibers. The coform material can also include other materials, such assuperabsorbent material. The meltblown fibers and absorbent fibers (andother optional materials) can be collected on a forming surface, such asprovided by a foraminous belt. The forming surface can include agas-pervious material that has been placed onto the forming surface.Coform materials are further described in U.S. Pat. Nos. 5,508,102 and5,350,624 to Georger et al. and U.S. Pat. No. 4,100,324 to Anderson andU.S. Publication No. 2012/0053547 to Schroeder et al., which areincorporated herein in their entirety by reference thereto and to theextent they do not conflict herewith. As used herein, the term“resilient coform” refers to a resilient coform nonwoven layer includinga matrix of meltblown fibers and an absorbent material, wherein themeltblown fibers constitute from about 30 wt % to about 99 wt % of theweb and the absorbent material constitutes from about 1 wt % to about 70wt % of the web, and further wherein the meltblown fibers being formedfrom a thermoplastic composition that contains at least onepropylene/α-olefin copolymer having a propylene content of from about 60mole % to about 99.5 mole % and an α-olefin content of from about 0.5mole % to about 40 mole %, wherein the copolymer further has a densityof from about 0.86 to about 0.90 grams per cubic centimeter and thecomposition has a melt flow rate of from about 120 to about 6000 gramsper 10 minutes, determined at 230° C. in accordance with ASTM TestMethod D1238-E, although practical considerations can reduce the highend melt flow rate range.

The acquisition layer 84 may have additional parameters including basisweight and thickness. In an embodiment, the basis weight of theacquisition layer 84 can be at least about 10 or 20 gsm. In anembodiment, the basis weight of the acquisition layer 84 can be fromabout 10, 20, 30, 40, 50 or 60 gsm to about 65, 70, 75, 80, 85, 90, 100,110, 120, or 130 gsm. In an embodiment, the basis weight of theacquisition layer 84 can be less than about 130, 120, 110, 100, 90, 85,80, 75, 70, 65, 60 or 50 gsm. In an embodiment, the acquisition layer 84can have a thickness, measured at 0.05 psi (0.345 kPa), of less thanabout 1.5 mm. In an embodiment, such as, for example, when the absorbentarticle 10 can be a diaper, the acquisition layer 84 can have athickness, measured at 0.05 psi (0.345 kPa), of less than about 1.5,1.25, or 1.0 mm. In an embodiment, such as, for example, when theabsorbent article can be a feminine hygiene product, the acquisitionlayer 84 can have a thickness, measured at 0.2 psi (1.379 kPa), of lessthan about 1.5, 1.25, or 1.0 mm.

Body Facing Material:

As illustrated in FIGS. 7-9, a body facing material 28 can be a fluidentangled laminate web with projections 90 extending outwardly and awayfrom at least one intended external surface of the laminate web. In anembodiment, the projections 90 can be hollow. The body facing material28 can have two layers such as a support layer 92 and a projection layer94. The support layer 92 can have a first surface 96 and an opposedsecond surface 98 as well as a thickness 100. The projection layer 94can have an inner surface 102 and an opposed outer surface 104 as wellas a thickness 106. An interface 108 can be present between the supportlayer 92 and the projection layer 94. In an embodiment, fibers of theprojection layer 94 can cross the interface 108 and be entangled withand engage the support layer 92 so as to form the body facing material28. In an embodiment in which the support layer 92 is a fibrous nonwovenweb, the fibers of the support layer 92 may cross the interface 108 andbe entangled with the fibers in the projection layer 94.

Projections of Body Facing Material

In an embodiment, the projections 90 can be filled with fibers from theprojection layer 94 and/or the support layer 92. In an embodiment, theprojections 90 can be hollow. The projections 90 can have closed ends110 which can be devoid of apertures. In some embodiments, however, itmay be desirable to increase the pressure and/or dwell time of theimpinging fluid jets in the entangling process as described herein tocreate one or more apertures (not shown) in each of the projections 90.Apertures can also be formed into the body facing material via formingposts (not shown) which can be located on the projection forming surface156 (such as forming surface 156 in FIGS. 12 and 12A). Such aperturesmay be formed in the closed ends 110 and/or side walls 112 of theprojections 90. Such apertures are to be distinguished from interstitialfiber-to-fiber spacing which is the spacing from one individual fiber tothe next individual fiber.

In various embodiments, the projections 90 can have a percentage of openarea in which light can pass through the projections 90 unhindered bythe material forming the projections 90, such as, for example, fibrousmaterial. The percentage of open area present in the projections 90encompasses all area of the projection 90 where light can pass throughthe projection 90 unhindered. Thus, for example, the percentage of openarea of a projection 90 can encompass all open area of the projection 90via apertures, interstitial fiber-to-fiber spacing, and any otherspacing within the projection 90 where light can pass throughunhindered. In an embodiment, the projections 90 can be formed withoutapertures and the open area can be due to the interstitialfiber-to-fiber spacing. In various embodiments, the projections 90 canhave less than about 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1%open area in a chosen area of the body facing material 28 as measuredaccording to the Method to Determine Percent Open Area test methoddescribed herein.

In an embodiment, such as the non-limiting embodiment illustrated inFIG. 10, the projections 90 can be round when viewed from above withsomewhat domed or curved tops or closed ends 110, such as seen whenviewed in a cross-section such as shown in FIGS. 10A and 10B. The actualshape of the projections 90 can be varied depending on the shape of theforming surface into which the fibers from the projection layer 94 areforced. Thus, while not limiting the variations, the shapes of theprojections 90 may be, for example, round, oval, square, rectangular,triangular, diamond-shaped, etc. Both the width and height of theprojections 90 can be varied as can be the spacing and pattern of theprojections 90. In an embodiment, various shapes, sizes and spacing ofthe projections 90 can be utilized in the same projection layer 94. Inan embodiment, the projections 90 can have a height, measured accordingto the Method to Determine Percent Open Area test method describedherein, of greater than about 1 mm. In an embodiment, the projections 90can have a height greater than about 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10mm. In an embodiment, the projections 90 can have a height from about 1,2, 3, 4, or 5 mm to about 6, 7, 8, 9 or 10 mm.

The projections 90 of the body facing material 28 can be located on andemanate from the outer surface 104 of the projection layer 94. In anembodiment, the projections 90 can extend from the outer surface 104 ofthe projection layer 94 in a direction away from the support layer 92.In an embodiment in which the projections 90 can be hollow, they canhave open ends 114 which can be located towards the inner surface 102 ofthe projection layer 94 and can be covered by the second surface 98 ofthe support layer 92 or the inner surface 102 of the projection layer 94depending upon the amount of fiber that has been used from theprojection layer 94 to form the projections 90. The projections 90 canbe surrounded by land areas 116 which can be formed from the outersurface 104 of the projection layer 94 though the thickness of the landareas 116 can be comprised of both the projection layer 94 and thesupport layer 92. The land areas 116 can be relatively flat and planar,as shown in FIGS. 7 and 8, or topographical variability may be builtinto the land areas 116. For example, in an embodiment, a land area 116may have a plurality of three-dimensional shapes formed into it byforming the projection layer 94 on a three-dimensionally-shaped formingsurface such as is disclosed in U.S. Pat. No. 4,741,941 to Engelbert etal. assigned to Kimberly-Clark Worldwide and incorporated herein byreference in its entirety for all purposes. For example, in anembodiment, a land area 116 may be provided with depressions 118 whichcan extend all or part way into the projection layer 94 and/or thesupport layer 92. In addition, a land area 116 may be subjected toembossing which can impart surface texture and other functionalattributes to the land area 116. In an embodiment, a land area 116 andthe body facing material 28 as a whole may be provided with apertures120 which can extend through the body facing material 28 so as tofurther facilitate the movement of fluids (such as the liquids andsolids that make up body exudates) into and through the body facingmaterial 28. Such apertures 120 are to be distinguished frominterstitial fiber-to-fiber spacing, which is the spacing from oneindividual fiber to the next individual fiber.

In various embodiments, the land areas 116 can have a percentage of openarea in which light can pass through the land areas 116 unhindered bythe material forming the land areas 116, such as, for example, fibrousmaterial. The percentage of open area present in the land areas 116encompasses all area of the land areas 116 where light can pass throughthe land areas 116 unhindered. Thus, for example, the percentage of openarea of a land area 116 can encompass all open area of the land areas116 via apertures, interstitial fiber-to-fiber spacing, and any otherspacing within the land areas 116 where light can pass throughunhindered. In various embodiments, the land areas 116 can have greaterthan about 1% open area in a chosen area of the body facing material 28,as measured according to the Method to Determine Percent Open Area testmethod described herein. In an embodiment, the land areas 116 can beformed without apertures and the open area can be due to theinterstitial fiber-to-fiber spacing. In various embodiments, the landareas 116 can have greater than about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,12, 13, 14, 15, 16, 17, 18, 19 or 20% open area in a chosen area of thebody facing material 28. In various embodiments, the land areas 116 canhave about 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8,8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5,16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, or 20% open area in a chosenarea of the body facing material 28. In various embodiments, the landareas 116 can have from about 1, 2 or 3% to about 4 or 5% open area in achosen area of the body facing material. In various embodiments, theland areas 116 can have from about 5, 6 or 7% to about 8, 9 or 10% openarea in a chosen area of the body facing material 28. In variousembodiments, the land areas 116 can have from about 10, 11, 12, 13, 14or 15% to about 16, 17, 18, 19 or 20% open area in a chosen area of thebody facing material 28. In various embodiments, the land areas 116 canhave greater than about 20% open area in a chosen area of the bodyfacing material 28.

The projections 90 of the body facing material 28 can be provided in anyorientation as deemed suitable. In an embodiment, the projections 90 ofthe body facing material 28 can be provided randomly to the body facingmaterial 28. In an embodiment, the projections 90 can be orientedlinearly in the longitudinal direction 30 of the absorbent article 10.In an embodiment, the projections 90 can be oriented linearly in thelateral direction 32 of the absorbent article 10. In an embodiment, theprojections 90 can be oriented linearly in a direction which can be atan angle to the longitudinal direction 30 and/or the lateral direction32 of the absorbent article 10. The land areas 116 of the body facingmaterial 28 can be provided in any orientation as deemed suitable. In anembodiment, the land areas 116 can be oriented linearly in thelongitudinal direction 30 of the absorbent article 10. In an embodiment,the land areas 116 can be oriented linearly in the lateral direction 32of the absorbent article 10. In an embodiment, the land areas 116 can beoriented linearly in a direction which can be at an angle to thelongitudinal direction 30 and/or the lateral direction 32 of theabsorbent article 10.

In an embodiment, the projections 90 and/or the land areas 116 can beprovided such that the projections 90 are located in the crotch region16 of the absorbent article 10, are located towards the perimeter of theabsorbent article 10, and combinations thereof. In an embodiment, theprojections 90 can have varying heights in different areas of theabsorbent article 10. In such an embodiment, for example, theprojections 90 can have a first height in an area of the absorbentarticle 10 and a different height in a different area of the absorbentarticle 10. In an embodiment, the projections 90 can have varyingdiameters in different areas of the absorbent article 10. In such anembodiment, for example, the projections 90 can have a first diameter inan area of the absorbent article 10 and can have a different diameter ananother area of the absorbent article 10. In an embodiment, theconcentration of projections 90 can vary in the absorbent article 10. Insuch an embodiment, an area of the absorbent article 10 can have ahigher concentration of projections 90 than the concentration ofprojections 90 in a second area of the absorbent article 10.

In an embodiment, the projections 90 and/or the land areas 116 can beprovided in a patterned orientation. Non-limiting examples of patternedorientations can include, but are not limited to, lines, circles,squares, rectangles, triangles, ovals, stars, and hexagons. In anembodiment, a patterned orientation can be provided such that thepatterned orientation is parallel with the longitudinal direction 30and/or the lateral direction 32 of the absorbent article 10. In anembodiment, a patterned orientation can be provided such that thepatterned orientation is at an angle to the longitudinal direction 30and/or the lateral direction 32 of the absorbent article 10. In anembodiment, a projection 90 of the body facing material 28 can be atleast partially aligned, completely aligned, or completely non-alignedwith another projection 90 of the body facing material 28, such as, forexample, an adjacent projection 90. Without being bound by theory, it isbelieved that the alignment (whether partial, complete alignment orcomplete non-alignment) of a projection 90 of the body facing material28 with another projection 90, such as an adjacent projection 90, of thebody facing material 28 can result in channels of land areas 116 whichcan impede further spread of body exudates along the body facingmaterial 28 of the absorbent article 10 and/or can direct the spread ofbody exudates towards desired locations of the body facing material 28of the absorbent article 10.

As illustrative examples, FIGS. 11A, 11B and 11C provide illustrationsof an exemplary embodiment of partial alignment, complete alignment andcomplete non-alignment of two projections in adjacent lines ofprojection. In the embodiment illustrated, for example, in FIG. 11A, afirst line 91 of projections 90 can be arranged linearly in a directionthat is parallel with the longitudinal direction 30 of the absorbentarticle 10. In such an embodiment, a projection 90 of a first line 91 ofprojections 90 which are oriented in a direction parallel to thelongitudinal direction 30 of the absorbent article can be at leastpartially aligned with a projection 90 of an immediately adjacent secondline 93 of projections 90 which are oriented in a direction parallel tothe longitudinal direction 30 of the absorbent article. In such anembodiment, a partial alignment of a projection 90 of a first line 91 ofprojections 90 which are oriented in a direction parallel to thelongitudinal direction 30 of the absorbent article 10 with a projection90 of an immediately adjacent second line 93 of projections 90 which isoriented in a direction parallel to the longitudinal direction 30 of theabsorbent article 10 can result in the passage of an imaginary line 95in the lateral direction 32 of the absorbent article 10 through each ofthe projections 90 of the first 91 and second 93 lines of projections90. It should be understood that the passage of the imaginary line 95through each of the projections 90 of the first 91 and second 93 linesof projections 90 does not necessarily result in a passage through themidpoint of each of the projections 90 of the first 91 and second 93lines of projections 90. In the embodiment illustrated, for example, inFIG. 11B, a first line 91 of projections 90 can be arranged linearly ina direction that is parallel with the longitudinal direction 30 of theabsorbent article 10. In such an embodiment, a projection 90 of a firstline 91 of projections 90 which are oriented in a direction parallel tothe longitudinal direction 30 of the absorbent article 10 can becompletely aligned with a projection 90 of an immediately adjacentsecond line 93 of projections 90 which are oriented in a directionparallel to the longitudinal direction 30 of the absorbent article 10.In such an embodiment, a complete alignment of a projection 90 of afirst line 91 of projections 90 which are oriented in a directionparallel to the longitudinal direction 30 of the absorbent article 10with a projection 90 of an immediately adjacent second line 93 ofprojections 90 which is oriented in a direction parallel to thelongitudinal direction 30 of the absorbent article 10 can result in thepassage of an imaginary line 95 in the lateral direction 32 of theabsorbent article 10 through each of the projections 90 of the first 91and second 93 lines of projections 90. In such an embodiment, theimaginary line 95 could pass through the midpoint of each of theprojections 90 of the first 91 and second 93 lines of projections 90. Inthe embodiment illustrated, for example, in FIG. 11C, a first line 91 ofprojections 90 can be arranged linearly in a direction that is parallelwith the longitudinal direction 30 of the absorbent article 10. In suchan embodiment, a projection 90 of a first line 91 of projections 90which are oriented in a direction parallel to the longitudinal direction30 of the absorbent article 10 can be completely non-aligned with aprojection 90 of an immediately adjacent second line 93 of projections90 which are oriented in a direction parallel to the longitudinaldirection 30 of the absorbent article 10. In such an embodiment, acomplete non-alignment of a projection 90 of a first line 91 ofprojections 90 which are oriented in a direction parallel to thelongitudinal direction 30 of the absorbent article 10 with a projection90 of an immediately adjacent second line 93 of projections 90 which isoriented in a direction parallel to the longitudinal direction 30 of theabsorbent article 10 can result in the passage of an imaginary line 95in the lateral direction 32 of the absorbent article 10 through only oneof the projections 90 or through neither of the projections 90 of thefirst 91 and second lines 93 of projections 90. It should be understoodthat additional configurations of partial alignment, complete alignmentand complete non-alignment can be formed.

While it is possible to vary the density and fiber content of theprojections 90, in an embodiment, the projections 90 can be “hollow”.Referring to FIGS. 10A and 10B, it can be seen that when the projections90 are hollow, they can have a shell 122 formed from the fibers of theprojection layer 94. The shell 122 can define an interior space 124which can have a lower density of fibers as compared to the shell 122 ofthe projections 90. By “density” it is meant the fiber count or contentper chosen unit of volume within a portion of the interior space 124 orthe shell 122 of the projection 90. The distance 103 between theexternal facing surface of the shell 122 to the inner facing surface ofthe shell 122 as well as the density of the shell 122 may vary within aparticular or individual projection 90 and it also may vary as betweendifferent projections 90. In addition, the size of the hollow interiorspace 124 as well as its density may vary within a particular orindividual projection 90 and it also may vary as between differentprojections 90. The photomicrographs of FIGS. 10A and 10B reveal a lowerdensity or count of fibers in the interior space 124 as compared to theshell 122 of the illustrated projection 90. As a result, if there is atleast some portion of an interior space 124 of a projection 90 that hasa lower fiber density than at least some portion of the shell 122 of thesame projection 90, then the projection is regarded as being “hollow”.In this regard, in some situations, there may not be a well-defineddemarcation between the shell 122 and the interior space 124 but, ifwith sufficient magnification of a cross-section of one of theprojections, it can be seen that at least some portion of the interiorspace 124 of the projection 90 has a lower density than some portion ofthe shell 122 of the same projection 90, then the projection 90 isregarded as being “hollow”. Further, if at least a portion of theprojections 90 of a body facing material 28 are hollow, the projectionlayer 94 and the body facing material 28 are regarded as being “hollow”or as having “hollow projections”. In an embodiment, the portion of theprojections 90 which are hollow can be greater than or equal to about 50percent of the projections 90 in a chosen area of the body facingmaterial 28. In an embodiment, greater than or equal to about 70 percentof the projections 90 in a chosen area of the body facing material 28can be hollow. In an embodiment, greater than or equal to about 90percent of the projections 90 in a chosen area of the body facingmaterial 28 can be hollow.

As will become more apparent in connection with the description of theprocesses set forth below, the body facing material 28 can be the resultof the movement of the fibers in the projection layer 94 in one andsometimes two or more directions. Referring to FIG. 9, if the formingsurface (such as forming surface 156 in FIGS. 12 and 12A) upon which theprojection layer 94 is placed is solid except for the forming holes(such as forming holes 170 in FIG. 12A) used to form the projections 90,then the force of the fluid entangling streams hitting and reboundingoff the solid surface land areas (such as land areas 172 in FIG. 12A)corresponding to the land areas 116 of the projection layer 94 can causea migration of fibers adjacent the inner surface 102 of the projectionlayer 94 into the support layer 92 adjacent its second surface 98. Thismigration of fibers in the first direction can be represented by thearrows 126 shown in FIG. 9. In order to form the projections 90extending outwardly from the outer surface 104 of the projection layer94, there must be a migration of fibers in a second direction as shownby the arrows 128. It is this migration in the second direction whichcauses fibers from the projection layer 94 to move out and away from theouter surface 104 to form the projections 90.

In an embodiment in which the support layer 92 can be a fibrous nonwovenweb, depending on the degree of web integrity and the strength and dwelltime of the fluid jets, there also may be a movement of support layer 92fibers into the projection layer 94 as shown by arrows 130 in FIG. 9.The net result of these fiber movements can be the creation of a bodyfacing material 28 with good overall integrity and lamination of thelayers (92 and 94) at their interface 108 thereby allowing furtherprocessing and handling of the body facing material 28. As a result ofthe fluid entanglement processes described herein, it is generally notdesirable that the fluid pressure used to form the projections 90 be ofsufficient force so as to force fibers from the support layer 92 to beexposed on the outer surface 104 of the projection layer 94.

Support Layer and Projection Layer of Body Facing Material

As the name implies, the support layer 92 can support the projectionlayer 94 containing the projections 90 and can be made from a number ofstructures provided the support layer 92 can be capable of supportingthe projection layer 94. The primary functions of the support layer 92can be to protect the projection layer 94 during the formation of theprojections 90, to be able to bond to or be entangled with theprojection layer 94 and to aid in further processing of the projectionlayer 94 and the resultant body facing material 28. Suitable materialsfor the support layer 92 can include, but are not limited to, nonwovenfabrics or webs, scrim materials, netting materials,paper/cellulose/wood pulp-based products which can be considered asubset of nonwoven fabrics or webs as well as foam materials, films andcombinations of the foregoing provided the material or materials chosenare capable of withstanding a process of manufacture such as afluid-entangling process. In an embodiment, the support layer 92 can bea fibrous nonwoven web made from a plurality of randomly depositedfibers which may be staple length fibers such as are used, for example,in carded webs, air laid webs, etc. or they may be more continuousfibers such as are found in, for example, meltblown or spunbond webs.Due to the functions the support layer 92 must perform, the supportlayer 92 can have a higher degree of integrity than the projection layer94. In this regard, the support layer 92 can remain substantially intactwhen it is subjected to the fluid-entangling process discussed ingreater detail below. The degree of integrity of the support layer 92can be such that the material forming the support layer 92 can resistbeing driven down into and filling the projections 90 of the projectionlayer 94. As a result, in an embodiment in which the support layer 92 isa fibrous nonwoven web, it should have a higher degree of fiber-to-fiberbonding and/or fiber entanglement than the fibers in the projectionlayer 94. While it can be desirable to have fibers from the supportlayer 92 entangle with the fibers of the projection layer 94 adjacentthe interface 108 between the two layers, it is generally desired thatthe fibers of this support layer 92 not be integrated or entangled intothe projection layer 94 to such a degree that large portions of thesefibers find their way inside the projections 90.

In an embodiment, a function of the support layer 92 can be tofacilitate further processing of the projection layer 94. In anembodiment, the fibers used to form the projection layer 94 can be moreexpensive than those used to form the support layer 92. As a result, insuch an embodiment, it can be desirable to keep the basis weight of theprojection layer 94 low. In so doing, however, it can become difficultto process the projection layer 94 subsequent to its formation. Byattaching the projection layer 94 to an underlying support layer 92,further processing, winding and unwinding, storage and other activitiescan be done more effectively.

In order to resist the higher degree of fiber movement, as mentionedabove, in an embodiment, the support layer 92 can have a higher degreeof integrity than the projection layer 94. This higher degree ofintegrity can be brought about in a number of ways. One can befiber-to-fiber bonding which can be achieved through thermal orultrasonic bonding of the fibers to one another with or without the useof pressure as in through-air bonding, point bonding, powder bonding,chemical bonding, adhesive bonding, embossing, calender bonding, etc. Inaddition, other materials may be added to the fibrous mix such asadhesives and/or bicomponent fibers. Pre-entanglement of a fibrousnonwoven support layer 92 may also be used such as, for example, bysubjecting the web to hydroentangling, needlepunching, etc., prior tothis support layer 92 being joined to a projection layer 94.Combinations of the foregoing are also possible. Still other materialssuch as foams, scrims and nettings may have enough initial integrity soas to not need further processing. The level of integrity can in manycases be visually observed due to, for example, the observation with theunaided eye of such techniques as point bonding which is commonly usedwith fibrous nonwoven webs such as spunbond webs and staplefiber-containing webs. Further magnification of the support layer 92 mayalso reveal the use of fluid-entangling or the use of thermal and/oradhesive bonding to join the fibers together. Depending on whethersamples of the individual layers (92 and 94) are available, tensiletesting in either or both of the machine and cross-machine directionsmay be undertaken to compare the integrity of the support layer 92 tothe projection layer 94. See for example ASTM test D5035-11 which isincorporated herein its entirety for all purposes.

The type, basis weight, tensile strength and other properties of thesupport layer 92 can be chosen and varied depending upon the particularend use of the resultant body facing material 28. When the body facingmaterial 28 is to be used as part of an absorbent article such as apersonal care absorbent article, wipe, etc., it can be generallydesirable that the support layer 92 be a layer that is fluid pervious,has good wet and dry strength, is able to absorb fluids such as bodyexudates, possibly retain the fluids for a certain period of time andthen release the fluids to one or more subjacent layers. In this regard,fibrous nonwovens such as spunbond webs, meltblown webs and carded webssuch as airlaid webs, bonded carded webs and coform materials arewell-suited as support layers 92. Foam materials and scrim materials arealso well-suited. In addition, the support layer 92 may be amulti-layered material due to the use of several layers or the use ofmulti-bank formation processes as are commonly used in making spunbondwebs and meltblown webs as well as layered combinations of meltblown andspunbond webs. In the formation of such support layers 92, both naturaland synthetic materials may be used alone or in combination to fabricatethe materials. In various embodiments, the support layer 92 can have abasis weight ranging from about 5 to about 40 or 50 gsm.

The type, basis weight and porosity of the support layer 92 can affectthe process conditions necessary to form the projections 90 in theprojection layer 94. Heavier basis weight materials can increase theentangling force of the entangling fluid streams needed to form theprojections 90 in the projection layer 94. However, heavier basis weightsupport layers 92 can also provide improved support for the projectionlayer 94 as it has been determined that the projection layer 94 byitself is too stretchy to maintain the shape of the projections 90 postthe formation process. The projection layer 94 by itself can undulyelongate in the machine direction due to the mechanical forces exertedon it by subsequent winding and converting processes and consequentlydiminish and distort the projections. Also, without the support layer92, the projections 90 in the projection layer 94 tend to collapse dueto the winding pressures and compressive weights the projection layer 94experiences in the winding process and subsequent conversion and do notrecover to the extent they do when a support layer 94 is present.

The support layer 92 may be subjected to further treatment and/oradditives to alter or enhance its properties. For example, surfactantsand other chemicals may be added both internally and externally to thecomponents forming all or a portion of the support layer 92 to alter orenhance its properties. Compounds commonly referred to as hydrogels orsuperabsorbents which absorb many times their weight in liquids may beadded to the support layer 92 in both particulate and fiber form.

The projection layer 94 can be made from a plurality of randomlydeposited fibers which may be staple length fibers such as are used, forexample, in carded webs, airlaid webs, coform webs, etc., or they may bemore continuous fibers such as are found in, for example, meltblown orspunbond webs. The fibers in the projection layer 94 can have lessfiber-to-fiber bonding and/or fiber entanglement and thus less integrityas compared to the integrity of the support layer 92, especially inembodiments when the support layer 92 is a fibrous nonwoven web. In anembodiment, the fibers in the projection layer 94 may have no initialfiber-to-fiber bonding for purposes of allowing the formation of theprojections 90 as will be explained in further detail below inconnection with the description of one or more of the embodiments of theprocess and apparatus for forming the body facing material 28.Alternatively, when both the support layer 92 and the projection layer94 can both be fibrous nonwoven webs, the projection layer 94 can haveless integrity than the support layer 92 due to the projection layer 94having, for example, less fiber-to-fiber bonding, less adhesive or lesspre-entanglement of the fibers forming the projection layer 94.

The projection layer 94 can have a sufficient amount of fiber movementcapability to allow the below-described fluid entangling process to beable to move a first plurality of the plurality of fibers of theprojection layer 94 out of the X-Y plane of the projection layer 94 andinto the perpendicular or Z-direction of the projection layer 94 so asto be able to form the projections 90 (illustrated in FIG. 7). As notedherein, in various embodiments, the projections 90 can be hollow. Asdescribed herein, in an embodiment, a second plurality of the pluralityof fibers in the projection layer 94 can become entangled with thesupport layer 92. If more continuous fiber structures are being usedsuch as meltblown or spunbond webs, in an embodiment, there may belittle or no pre-bonding of the projection layer 94 prior to the fluidentanglement process. Longer fibers such as are generated in meltblowingand spunbonding processes (which are often referred to as continuousfibers to differentiate them from staple length fibers) will typicallyrequire more force to displace the fibers in the Z-direction than willshorter, staple length fibers that typically have fiber lengths lessthan about 100 mm and more typically fibers lengths in the 10 to 60 mmrange. Conversely, staple fiber webs such as carded webs and airlaidwebs can have some degree of pre-bonding or entanglement of the fibersdue to their shorter length. Such shorter fibers require less fluidforce from the fluid entangling streams to move them in the Z-directionto form the projections 90. As a result, a balance must be met betweenfiber length, degree of pre-fiber bonding, fluid force, web speed anddwell time so as to be able to create the projections 90 without, unlessdesired, forming apertures in the land areas 116 or the projections 90or forcing too much material into the interior space 124 of theprojections 90 thereby making the projections 90 too rigid for someend-use applications.

In various embodiments, the projection layer 94 can have a basis weightranging from about 10 gsm to about 60 gsm. Spunbond webs can typicallyhave basis weights of between about 15 and about 50 gsm when being usedas the projection layer 94. Fiber diameters can range between about 5and about 20 microns. The fibers may be single component fibers formedfrom a single polymer composition or they may be bicomponent ormulticomponent fibers wherein one portion of the fiber can have a lowermelting point than the other components so as to allow fiber-to-fiberbonding through the use of heat and/or pressure. Hollow fibers may alsobe used. The fibers may be formed from any polymer formulationstypically used to form spunbond webs. Examples of such polymers include,but are not limited to, polypropylene (“PP”), polyester (“PET”),polyamide (“PA”), polyethylene (“PE”) and polylactic acid (“PLA”). Thespunbond webs may be subjected to post-formation bonding and entanglingtechniques if necessary to improve the processability of the web priorto its being subjected to the projection forming process.

Meltblown webs can typically have basis weights of between about 20 andabout 50 gsm when being used as the projection layer 94. Fiber diameterscan range between about 0.5 and about 5 microns. The fibers may besingle component fibers formed from a single polymer composition or theymay be bicomponent or multicomponent fibers wherein one portion of thefiber can have a lower melting point than the other components so as toallow fiber-to-fiber bonding through the use of heat and/or pressure.The fibers may be formed from any polymer formulations typically used toform spunbond webs. Examples of such polymers include, but are notlimited to, PP, PET, PA, PE and PLA.

Carded and airlaid webs can use staple fibers that can typically rangein length between about 10 and about 100 millimeters. Fiber denier canrange between about 0.5 and about 6 denier depending upon the particularend use. Basis weights can range between about 20 and about 60 gsm. Thestaple fibers may be made from a wide variety of polymers including, butnot limited to, PP, PET, PA, PE, PLA, cotton, rayon, flax, wool, hempand regenerated cellulose such as, for example, Viscose. Blends offibers may be utilized too, such as blends of bicomponent fibers andsingle component fibers as well as blends of solid fibers and hollowfibers. If bonding is desired, it may be accomplished in a number ofways including, for example, through-air bonding, calender bonding,point bonding, chemical bonding and adhesive bonding such as powderbonding. If needed, to further enhance the integrity and processabilityof a projection layer 94 prior to the projection forming process, theprojection layer 94 may be subjected to pre-entanglement processes toincrease fiber entanglement within the projection layer 94 prior to theformation of the projections 90. Hydroentangling can be advantageous inthis regard.

While the foregoing nonwoven web types and formation processes describedherein are suitable for use in conjunction with the projection layer 94,it is anticipated that other webs and formation processes may also beused provided the webs are capable of forming the projections 90.

The support layer 92 and the projection layer 94 each can be made at avariety of basis weights depending upon the particular end application.For example, the body facing material 28 can have an overall basisweight from about 15, 20 or 25 to about 100, 110 or 120 gsm and thesupport layer 92 can have a basis weight from about 5 to about 40 or 50gsm while the projection layer 94 can have a basis weight from about 15or 20 to about 50 or 60 gsm. Such basis weight ranges can be possibledue to the manner in which the body facing material 28 can be formed andthe use of two different layers with different functions relative to theformation process. As a result, the body facing material 28 can be madein commercial settings which heretofore were not considered possible dueto the inability to process the individual webs and form the desiredprojections 90.

In an embodiment, the body facing material 28 of an absorbent article 10can have a load of more than about 2 Newtons per 25 mm width at a 10%extension in the machine direction. In an embodiment, the body facingmaterial 28 of an absorbent article 10 can have a load of more thanabout 4 Newtons per 25 mm width at a 10% extension in the machinedirection. In an embodiment, the body facing material 28 of an absorbentarticle 10 can have a load of more than about 6 Newtons per 25 mm widthat a 10% extension in the machine direction. In various embodiments, thebody facing material 28 of an absorbent article 10 can have a resiliencyof greater than about 70%. In various embodiments, the body facingmaterial 28 of an absorbent article 10 can have a resiliency of greaterthan about 70, 73, 75, 77, 80, or 83%.

In various embodiments, the absorbent article 10 can be a diaper. Invarious embodiments, the amount of residual fecal material simulant onthe body facing material 28 of an absorbent article 10 following insultwith fecal material simulant as measured according to the Determinationof Residual Fecal Material Simulant test method described herein can beless than about 2.5, 2.4, 2.3, 2.2, 2.1, 2.0, 1.9, 1.8, 1.7, 1.6, or 1.5grams. In various embodiments, the area of spread of fecal materialsimulant on the body facing material 28 of an absorbent article 10following insult with fecal material simulant as measured according tothe Determination of Area of Spread of Fecal Material Simulant testmethod described herein can be less than about 34, 33, 32, 31, 30, or 29cm².

In various embodiments, the absorbent article 10 can be a femininehygiene product. In various embodiment, the second intake time through abody facing material 28 on an absorbent article 10 following insult witha menses simulant can be less than about 30, 20 or 15 seconds asmeasured using the Intake/Rewet test method described herein. In variousembodiments, the second intake time of menses simulant through a bodyfacing material 28 on an absorbent article 10 can be from about 25 or30% to about 50, 60 or 70% less than commercially available productfollowing insult with the menses simulant as measured using theIntake/Rewet test method described herein. In various embodiments, thesecond intake time through a body facing material 28 on an absorbentarticle 10 can be about 25, 30, 31, 47, 49, 50, 54, 60, 64, 66 or 70%less than commercially available products following insult with a mensessimulant as measured using the Intake/Rewet test method describedherein.

In various embodiment, the second intake time through a body facingmaterial 28 on an absorbent article 10 following insult with a mensessimulant can be less than about 30, 20 or 15 seconds without an increasein rewet amount as measured using the Intake/Rewet test method describedherein. In various embodiments, the second intake time of mensessimulant through a body facing material 28 on an absorbent article 10can be from about 25 or 30% to about 50, 60 or 70% less thancommercially available product without an increase in rewet amountfollowing insult with the menses simulant as measured using theIntake/Rewet test method described herein. In various embodiments, thesecond intake time through the body facing material 28 on an absorbentarticle 10 following insult with menses simulant can be about 25, 30,31, 47, 49, 50, 54, 60, 64, 66 or 70% less than commercially availableproducts without an increase in rewet amount.

Process for Making Body Facing Material

A fluid entangling process can be employed to form the body facingmaterial 28. Any number of fluids may be used to join the support layer92 and projection layer 94 together including both liquids and gases.The most common technology used in this regard can be referred to asspunlace or hydroentangling technology which can use pressurized wateras the fluid for entanglement.

Referring to FIG. 12 there is shown an embodiment of a process andapparatus for forming a fluid-entangled body facing material 28 withprojections 90. The apparatus 150 can include a first transport belt152, a transport belt drive roller 154, a projection forming surface156, a fluid entangling device 158, an optional overfeed roller 160, anda fluid removal system 162 such as a vacuum or other conventionalsucking device. Such vacuum devices and other means are well known tothose of ordinary skill in the art. The transport belt 152 can carry theprojection layer 94 into the apparatus 150. If any pre-entangling is tobe done on the projection layer 94 upstream of the process illustratedin FIG. 12, the transport belt 152 may be porous. The transport belt 152can travel in a first direction (which is the machine direction) asshown by arrow 164 at a first speed or velocity V1. The transport belt152 can be driven by a transport belt drive roller 154 or other suitablemeans as are well known to those of ordinary skill in the art.

The projection forming surface 156 as shown in FIG. 12 can be in theform of a texturizing drum and a partially exploded view of the surfaceis shown in FIG. 12A. The projection forming surface 156 can move in themachine direction as shown by arrow 166 at a speed or velocity V3. Itcan be driven and its speed can be controlled by any suitable drivemeans (not shown) such as electric motors and gearing as are well knownto those of ordinary skill in the art. The projection forming surface156 depicted in FIGS. 12 and 12A can have a forming surface 168containing a pattern of forming holes 170 that can correspond to theshape and pattern of the desired projections 90 in the projection layer94 and the forming holes 170 can be separated by a land area 172. Theforming holes 170 can be of any shape and any pattern. As can be seenfrom the Figures depicting the body facing material 28, the forming hole170 shapes can be round but it should be understood that any number ofshapes and combination of shapes can be used depending on the end useapplication. Examples of possible forming hole 170 shapes include, butare not limited to, ovals, crosses, squares, rectangles, diamond shapes,hexagons and other polygons. Such shapes can be formed in the projectionforming surface 156 by casting, punching, stamping, laser-cutting andwater-jet cutting. The spacing of the forming holes 170 and, therefore,the degree of land area 172 can also be varied depending upon theparticular end application of the body facing material 28. Further, thepattern of the forming holes 170 in the projection forming surface 156can be varied depending upon the particular end application of the bodyfacing material 28.

The material forming the projection forming surface 156 may be anynumber of suitable materials commonly used for forming such surfacesincluding, but not limited to, sheet metal, plastics and other polymermaterials, rubber, etc. The forming holes 170 can be formed in a sheetof the material that is then formed into a projection forming surface156 or the projection forming surface 156 can be molded or cast fromsuitable materials or printed with 3D printing technology. Theprojection forming surface 156 can be removably fitted onto and over anoptional porous inner drum shell 174 so that different forming surfaces168 can be used for different end product designs. The porous inner drumshell 174 can interface with the fluid removal system 162 which canfacilitate pulling the entangling fluid and fibers down into the formingholes 170 in the outer forming surface 168 thereby forming theprojections 90 in the projection layer 94. The porous inner drum shell174 can also act as a barrier to retard further fiber movement down intothe fluid removal system 162 and other portions of the equipment therebyreducing fouling of the equipment. The porous inner drum shell 174 canrotate in the same direction and at the same speed as the projectionforming surface 156. In addition, to further control the height of theprojections 90, the distance between the inner drum shell 174 and theprojection forming surface 156 can be varied. In an embodiment in whicha porous inner drum shell is utilized, the distance between the outerfacing surface of the inner drum shell 174 and the inner facing surfaceof the projection forming surface 156 can range from about 0 to about 5mm.

The cross-sectional dimensions of the forming holes 170 and their depthcan influence the cross-section and height of the projections 90produced in the projection layer 94. In an embodiment, the forming hole170 depth in the projection forming surface 156 can correspond to theheight of the projections 90. In an embodiment, the depth of the formingholes 170 in the projection forming surface 156 can be from about 1 or 3mm to about 5 or 10 mm. In an embodiment, a forming hole 170cross-section size may be from about 2 or 3 mm to about 6 or 10 mm asmeasured along the major axis. In an embodiment, a forming hole 170spacing on a center-to-center basis can be from about 3 or 4 mm to about7 or 10 mm. The pattern of the spacing between forming holes 170 may bevaried and selected depending upon the particular end use. Some examplesof patterns include, but are not limited to, aligned patterns of rowsand/or columns, skewed patterns, hexagonal patterns, wavy patterns andpatterns depicting pictures, figures and objects. It should be notedthat each of the forming holes 170 depth, spacing, size, shape and otherparameters may be varied independently of one another and may be variedbased upon the particular end use of the body facing material 28 beingformed.

The land areas 172 in the forming surface 168 of the projection formingsurface 156 can be solid so as to not pass the entangling fluid 176emanating from the fluid entangling devices 158 but in some instances itmay be desirable to make the land areas 172 fluid permeable to furthertexturize the exposed surface of the projection layer 94. Alternatively,select areas of the forming surface 168 of the projection formingsurface 156 may be fluid pervious and other areas impervious. Forexample, a central zone (not shown) of the projection forming surface156 may be fluid pervious while lateral regions (not shown) on eitherside of the central zone may be fluid impervious. In addition, the landareas 172 in the forming surface 168 may have raised areas (not shown)formed in or attached thereto to form optional depressions 118 and/oroptional apertures 120 in the projection layer 94 and the body facingmaterial 28.

In the embodiment of the apparatus 150 shown in FIG. 12, the projectionforming surface 156 is shown in the form of a texturizing drum. Itshould be appreciated however that other means may be used to create theprojection forming surface 156. For example, a foraminous belt or wire(not shown) may be used which includes forming holes 170 formed in thebelt or wire at appropriate locations. Alternatively, flexiblerubberized belts which are impervious to the pressurized fluidentangling streams, save the forming holes 170, may be used. Such beltsand wires are well known to those of ordinary skill in the art as arethe means for driving and controlling the speed of such belts and wires.In an embodiment, a texturizing drum may be more advantageous forformation of a body facing material 28 as described herein because itcan be made with land areas 172 which can be smooth and impervious tothe entangling fluid 176 and which do not leave a wire weave pattern onthe outer surface 104 of the projection layer 94 as wire belts tend todo.

An alternative to a projection forming surface 156 with a forminghole-depth defining the projection height can be a drum shell that isthinner than the desired projection height but which can be spaced awayfrom the porous inner drum 174 surface on which it is wrapped. Thespacing may be achieved by any means that preferably does not otherwiseinterfere with the process of forming the projections 90 and withdrawingthe entangling fluid from the equipment. For example, one means can be ahard wire or filament that may be inserted between the projectionforming surface 156 and the porous inner drum 174 as a spacer or wrappedaround the inner porous drum 174 underneath the projection formingsurface 156 to provide the appropriate spacing. A drum shell depth ofless than about 2 mm can make it more difficult to remove the projectionlayer 94 and the body facing material 28 from the projection formingsurface 156 because the material of the projection layer 94 can expandor be moved by fluid flow into the overhanging area beneath theprojection forming surface 156 which in turn can distort the resultantbody facing material 28.

It has been found, however, that by using a support layer 92 inconjunction with the projection layer 94 as part of the formationprocess, distortion of the resultant two layer fluid entangled bodyfacing material 28 can be greatly reduced and generally facilitatescleaner removal of the body facing material 28 because the lessextensible, more dimensionally stable support layer 92 can take the loadwhile the body facing material 28 is removed from the projection formingsurface 156. The higher tension that can be applied to the support layer92, compared to a single projection layer 94, means that as the bodyfacing material 28 moves away from the projection forming surface 156,the projections 90 can exit the forming holes 170 smoothly in adirection roughly perpendicular to the forming surface 168 andco-axially with the forming holes 170 in the projection forming surface156. In addition, by using the support layer 92, processing speeds canbe increased.

To form the projections 90 in the projection layer 94 and to laminatethe support layer 92 and the projection layer 94 together, one or morefluid entangling devices 158 can be spaced above the projection formingsurface 156. The most common technology used in this regard can bereferred to as spunlace or hydroentangling technology which can usepressurized water as the fluid for entanglement. As an unbonded orrelatively unbonded web or webs forming the layers (92 and 94) can befed onto a projection forming surface 156, a multitude of high pressurefluid jets (not shown) from one or more fluid entangling devices 158 canmove the fibers of the webs and the fluid turbulence can cause thefibers to entangle. These fluid streams can cause the fibers to befurther entangled within the individual webs. The streams can also causefiber movement and entanglement at the interface of the two or more websthereby causing the webs to become joined together. Still further, ifthe fibers in a layer, such as the projection layer 94, are loosely heldtogether, they can be driven out of their X-Y plane and thus into theZ-direction to form the projections 90. Depending on the level ofentanglement needed, one or a plurality of such fluid entangling devices158 can be used.

In FIG. 12, a single fluid entangling device 158 is shown, but insucceeding Figures where multiple devices are used in various regions ofthe apparatus 150, they are labeled with letter designators such as 158a, 158 b, 158 c, 158 d, and 158 e. When multiple fluid entanglingdevices 158 are used, the entangling fluid pressure in each subsequentfluid entangling device 158 can be higher than the preceding one so thatthe energy imparted to the web or webs increases and so the fiberentanglement within or between the webs increases. This reducesdisruption of the overall evenness of the areal density of the web bythe pressurized fluid jets while achieving the desired level ofentanglement and hence bonding of the layers and formation of theprojections 90. The entangling fluid 176 of the fluid entangling devices158 can emanate from injectors via jet-strips (not shown) consisting ofa row or rows of pressurized fluid jets with small apertures of adiameter usually from about 0.08 to about 0.15 mm and spacing of around0.5 mm in the cross-machine direction. The pressure in the jets can bebetween about 5 bar and 400 bar but typically can be less than about 200bar except for heavy weight fluid entangled materials and whenfibrillation is required. Other jet sizes, spacings, numbers of jets andjet pressures can be used depending upon the particular end application.Such fluid entangling devices 158 are well known to those of ordinaryskill in the art and are readily available from such manufactures asFleissner of Germany and Andritz-Perfojet of France.

The fluid entangling device 158 can be provided with conventionalhydroentangling jet-strips. Typically, these jet-strips can bepositioned or spaced from about 5 millimeters to about 10 or 20millimeters from the projection forming surface 156 though the actualspacing can vary depending on the basis weights of the materials beingacted upon, the fluid pressure, the number of individual jets beingused, the amount of vacuum being used via the fluid removal system 162and the speed at which the equipment is being run.

In the embodiments shown in FIGS. 12 through 17 the fluid entanglingdevices 158 can be conventional hydroentangling devices, theconstruction and operation of which are well known to those of ordinaryskill in the art. See for example U.S. Pat. No. 3,485,706 to Evans, thecontent of which is incorporated herein by reference in its entirety forall purposes. Also see the description of the hydraulic entanglementequipment described by Honeycomb Systems, Inc., Biddeford, Me., in thearticle entitled “Rotary Hydraulic Entanglement of Nonwovens”, reprintedfrom INSIGHT '86 INTERNATIONAL ADVANCED FORMING/BONDING Conference, thecontents of which is incorporated herein by reference in its entiretyfor all purposes.

Referring to FIG. 12, the projection layer 94 can be fed into theapparatus 150 at a speed V1, the support layer 92 can be fed into theapparatus 150 at a speed V2 and the body facing material 28 can exit theapparatus 150 at a speed V3 which is the speed of the projection formingsurface 156. As will be explained in greater detail below, these speedsV1, V2 and V3 may be the same as one another or varied to change theformation process and the properties of the resultant body facingmaterial 28. Feeding both the projection layer 94 and the support layer92 into the apparatus 150 at the same speed (V1 and V2) can produce abody facing material 28 with the desired projections 90. Feeding boththe projection layer 94 and the support layer 92 into the apparatus 150at the same speed which can be faster than the machine direction speed(V3) of the projection forming surface 156 can also form the desiredprojections 90.

Also shown in FIG. 12 is an optional overfeed roller 160 which may bedriven at a speed Vf. The overfeed roller 160 may be run at the samespeed as the speed V1 of the projection layer 94 or it may be run at afaster speed to tension the projection layer 94 upstream of the overfeedroller 160 when overfeed is desired. Overfeed can occur when one or bothof the incoming layers (92 and 94) is fed onto the projection formingsurface 156 at a greater speed than the speed V3 of the projectionforming surface 156. It has been found that improved projectionformation in the projection layer 94 can be affected by feeding theprojection layer 94 onto the projection forming surface 156 at a higherspeed than the incoming speed V2 of the support layer 92. In addition,it has been discovered that improved properties and projection formationcan be accomplished by varying the feed speeds of the layers (92 and 94)and by also using the overfeed roller 160 just upstream of theprojection forming surface 156 to supply a greater amount of fiber viathe projection layer 94 for subsequent movement by the entangling fluid176 down into the forming holes 170 in the projection forming surface156. In particular, by overfeeding the projection layer 94 onto theprojection forming surface 156, improved projection formation can beachieved including increased projection height.

In order to provide an excess of fiber so that the height of theprojections 90 can be maximized, the projection layer 94 can be fed ontothe projection forming surface 156 at a greater surface speed (V1) thanthe projection forming surface 156 is traveling (V3). Referring to FIG.12, the projection layer 94 can be fed onto the projection formingsurface 156 at a speed V1 while the support layer 92 can be fed in at aspeed V2 and the projection forming surface 156 can be traveling at aspeed V3 which can be slower than V1 and can be equal to V2. Theoverfeed percent (OF), the ratio at which the projection layer 94 can befed onto the projection forming surface 156, can be defined asOF=[(V₁/V₃)−1])×100 where V₁ is the input speed of the projection layer94 and V₃ is the output speed of the resultant body facing material 28and the speed of the projection forming surface 156. (When the overfeedroller 160 is being used to increase the speed of the incoming materialonto the projection forming surface 156 it should be noted that thespeed V1 of the material after the overfeed roller 160 will be fasterthan the speed V1 upstream of the overfeed roller 160. In calculatingthe overfeed ratio, it is this faster speed V1 that should be used.)Good formation of the projections 90 has been found to occur when theoverfeed ratio is between about 10 and about 50 percent. Note too, thatthis overfeeding technique and ratio can be used with respect to notjust the projection layer 94 only but to a combination of the projectionlayer 94 and the support layer 92 as they are collectively fed onto theprojection forming surface 156.

In order to minimize the length of projection layer 94 that issupporting its own weight before being subjected to the entangling fluid176 and to avoid wrinkling and folding of the projection layer 94, theoverfeed roller 160 can be used to carry the projection layer 94 atspeed V1 to a position close to the texturizing zone 178 on theprojection forming surface 156. In the example illustrated in FIG. 12,the overfeed roller 160 can be driven off the transport belt 152 but itis also possible to drive it separately so as to not put undue stress onthe incoming projection layer 94. The support layer 92 may be fed intothe texturizing zone 178 separately from the projection layer 94 and ata speed V2 that may be greater than, equal to or less than theprojection forming surface 156 speed V3 and greater than, equal to, orless than the projection layer 94 speed V1. In an embodiment, thesupport layer 92 can be drawn into the texturizing zone 178 by itsfrictional engagement with the projection layer 94 positioned on theprojection forming surface 156 and so once on the projection formingsurface 156, the support layer 92 can have a surface speed close to thespeed V3 of the projection forming surface 156 or it may be positivelyfed into the texturizing zone 178 at a speed close to the projectionforming surface 156 speed of V3. The texturizing process can cause somecontraction of the support layer 92 in the machine direction. Theoverfeed of either the support layer 92 or the projection layer 94 canbe adjusted according to the particular materials and the equipment andconditions being used so that the excess material that is fed into thetexturizing zone 178 can be used up thereby avoiding any unsightlywrinkling in the resultant body facing material 28. As a result, the twolayers (92 and 94) can be under some tension at all times despite theoverfeeding process. The take-off speed of the body facing material 28can be arranged to be close to the projection forming surface 156 speedV3 such that excessive tension is not applied to the body facingmaterial 28 in its removal from the projection forming surface 156. Suchexcessive tension would be detrimental to the clarity and size of theprojections 90.

An alternate embodiment of the process and apparatus can be shown inFIG. 13 in which like reference numerals are used for like elements. Inthis embodiment the main differences relative to the process andapparatus shown in FIG. 12 are a pre-entanglement of the projectionlayer 94 to improve its integrity prior to further processing via apre-entanglement fluid entangling device 158 a; a lamination of theprojection layer 94 to the support layer 92 via a lamination fluidentangling device 158 b; and an increase in the number offluid-entangling devices 158 (referred to as projection fluid entanglingdevices 158 c, 158 d, and 158 e) and thus an enlargement of thetexturizing zone 178 on the projection forming surface 156 in theprojection forming portion of the process.

The projection layer 94 can be supplied to the apparatus 150 via thetransport belt 152. As the projection layer 94 travels on the transferbelt 152 it can be subjected to a first fluid entangling device 158 a toimprove the integrity of the projection layer 94. This can be referredto as pre-entanglement of the projection layer 94. As a result, thetransport belt 152 can be fluid pervious to allow the entangling fluid176 to pass through the projection layer 94 and the transport belt 152.To remove the delivered entangling fluid 176, as in FIG. 12, a fluidremoval system 162 may be used below the transport belt 152. The fluidpressure from the first fluid entangling device 158 a can be in therange from about 10 to about 50 bar.

The support layer 92 and the projection layer 94 can be fed to alamination forming surface 180 with the first surface 96 of the supportlayer 92 facing and contacting the lamination forming surface 180 andthe second surface 98 of the support layer 92 contacting the innersurface 102 of the projection layer 94. To entangle the two layers (92and 94) together, one or more fluid entangling devices 158 b can be usedin connection with the lamination forming surface 180 to affect fiberentanglement between the two layers (92 and 94). A fluid removal system162 can be used to dispose of the entangling fluid 176. To distinguishthe apparatus in this lamination portion of the overall process from thesubsequent projection forming portion where the projections are formed,this equipment and process are referred to as lamination equipment asopposed to projection forming equipment. Thus, this portion is referredto as using a lamination forming surface 180 and a lamination fluidentangling device 158 b which uses lamination fluid jets as opposed toprojection forming jets. The lamination forming surface 180 can bemovable in the machine direction of the apparatus 150 at a laminationforming surface speed and should be permeable to the entangling fluidemanating from the lamination fluid jets located in the lamination fluidentangling device 158 b. The lamination fluid entangling device 158 bcan have a plurality of lamination fluid jets which are capable ofemitting a plurality of pressurized lamination fluid streams ofentangling fluid 176 in a direction towards the lamination formingsurface 180. The lamination forming surface 180, when in theconfiguration of a drum as shown in FIG. 13, can have a plurality ofholes in its surface separated by land areas to make it fluid permeableor it can be made from conventional forming wire which is permeable aswell. In this portion of the apparatus 150, complete bonding of the twolayers (92 and 94) is not necessary. Process parameters for this portionof the equipment are similar to those for the projection forming portionand the description of the equipment and process in connection with FIG.12. Thus, the speeds of the layers (92 and 94) and the surfaces in thelamination forming portion of the equipment and process may be varied asexplained above with respect to the projection forming equipment andprocess described with respect to FIG. 12.

For example, the projection layer 94 may be fed into the laminationforming process and onto the support layer 92 at a speed that can begreater than the speed the support layer 92 can be fed onto thelamination forming surface 180. Relative to entangling fluid pressures,lower lamination fluid jet pressures can be desired in this portion ofthe equipment as additional entanglement of the layers can occur duringthe projection forming portion of the process. As a result, laminationforming pressures from the lamination entangling device 158 b can rangebetween about 30 and about 100 bar.

When the plurality of lamination fluid streams 176 in the laminationfluid entangling device 158 b are directed in a direction from the outersurface 104 of the projection layer 94 towards the lamination formingsurface 180, at least a portion of the fibers in the projection layer 94can become entangled with the support layer 92 to form a laminate web.Once the projection layer 94 and support layer 92 are joined into alaminate web, the laminate web can leave the lamination portion of theequipment and process (elements 158 b and 180) and can be fed into theprojection forming portion of the equipment and process (elements 156,158 c, 158 d, 158 e and optional 160). As with the process shown in FIG.12, the laminate web may be fed onto the projection forming surface 156at the same speed as the projection forming surface 156 is traveling orit may be overfed onto the projection forming surface 156 using theoverfeed roller 160 or by simply causing the laminate web to travel at aspeed V1 which is greater than the speed V3 of the projection formingsurface 156. As a result, the process variables described above withrespect to FIG. 12 may also be employed with the equipment and processshown in FIG. 13. In addition, as with the apparatus and materials inFIG. 12, if the overfeed roller 160 is used to increase the speed V1 ofthe laminate web as it comes in contact with the projection formingsurface 156, it is this faster speed V1 after the overfeed roller 160that should be used when calculating the overfeed ratio. The sameapproach can be used when calculating the overfeed ratio with theremainder of the embodiments shown in FIGS. 14-17 if overfeed ofmaterial is being employed.

In the projection forming portion of the equipment, a plurality ofpressurized projection fluid streams of entangling fluid 176 can bedirected from the projection fluid jets located in the projection fluidentangling devices (158 c, 158 d, and 158 e) into the laminate web in adirection from the first surface 96 of the support layer 92 towards theprojection forming surface 156 to cause a first plurality of the fibersof the projection layer 94 in the vicinity of the forming holes 170located in the projection forming surface 156 to be directed into theforming holes 170 to form the plurality of projections 90 which extendoutwardly from the outer surface 104 of the projection layer 94 therebyforming the fluid entangled body facing material 28. As with the otherprocesses, the body facing material 28 can be removed from theprojection forming surface 156 and, if desired, can be subjected to thesame or different further processing as described with respect to theprocess and apparatus of FIG. 12 such as drying to remove excessentangling fluid or further bonding or other steps. In the projectionforming portion of the equipment and apparatus 150, projection formingpressures from the projection fluid entangling devices, 158 c, 158 d,and 158 e, can range from about 80 to about 200 bar.

A further modification of the process and apparatus 150 of FIG. 13 canbe illustrated in FIG. 14. In FIG. 13, as well as the embodimentsillustrated in FIGS. 15 and 17, the fluid entangled body facing material28 can be subjected to a pre-lamination step by way of the laminationforming surface 180 and a lamination fluid entangling device(s) 158 b.In each of these configurations (FIGS. 13, 15 and 17), the material thatis in direct contact with the lamination forming surface 180 is thefirst surface 96 of the support layer 92. However, it is also possibleto invert the support layer 92 and the projection layer 94 such as isshown in FIG. 14 such that the outer surface 104 of the projection layer94 is the side that is in direct contact with the lamination formingsurface 180.

Another embodiment of the process and apparatus can be illustrated inFIG. 15. This embodiment can be similar to that shown in FIG. 13 exceptthat only the projection layer 94 may be subjected to pre-entanglementusing the fluid entangling devices 158 a and 158 b prior to theprojection layer 94 being fed into the projection forming portion of theequipment. In addition, the support layer 92 can be fed into thetexturizing zone 178 on the projection forming surface 156 in the samemanner as in FIG. 12 though the texturizing zone 178 can be suppliedwith multiple fluid entangling devices (158 c, 158 d and 158 e).

FIG. 16 depicts another embodiment of the process and apparatus which,like FIG. 13, can bring the projection layer 94 and the support layer 92into contact with one another for a lamination treatment in a laminationportion of the equipment and process utilizing a lamination formingsurface 180 (which can be the same element as the transport belt 152)and a lamination fluid entanglement device 158 b. In addition, like theembodiment of FIG. 13, in the texturizing zone 178 of the projectionforming portion of the process and apparatus 150, multiple projectionfluid entangling devices (158 c and 158 d) can be used.

FIG. 17 depicts another embodiment of the process and apparatus 150. InFIG. 17, the primary difference is that the projection layer 94 canundergo a first treatment with entangling fluid 176 via a projectionfluid entangling device 158 c in the texturizing zone 178 before thesecond surface 98 of the support layer 92 is brought into contact withthe inner surface 102 of the projection layer 94 for fluid entanglementvia the projection fluid entangling device 158 d. In this manner, aninitial formation of the projections 90 can begin without the supportlayer 92 being in place. As a result, it may be desirable that theprojection fluid entangling device 158 c be operated at a lower pressurethan the fluid entangling device 158 d. For example, the projectionfluid entangling device 158 c may be operated in a pressure range ofabout 100 to about 140 bar whereas the projection fluid entanglingdevice 158 d may be operated in a pressure range of about 140 to about200 bar. Other combinations and ranges of pressures can be chosendepending upon the operating conditions of the equipment and the typesand basis weights of the materials being used for the projection layer94 and the support layer 92.

In each of the embodiments of the process and apparatus 150, the fibersin the projection layer 94 can be sufficiently detached and mobilewithin the projection layer 94 such that the entangling fluid 176emanating from the projection fluid jets in the texturizing zone 178 canmove a sufficient number of the fibers out of the X-Y plane of theprojection layer 94 in the vicinity of the forming holes 170 in theprojection forming surface 156 and force the fibers down into theforming holes 170 thereby forming the projections 90 in the projectionlayer 94 of the body facing material 28. In addition, by overfeeding atleast the projection layer 94 into the texturizing zone 178, enhancedprojection formation can be achieved as shown by the examples andphotomicrographs.

Secondary Liner:

In various embodiments, the body facing material 28 of the absorbentarticle 10 can overlay the absorbent body 40 and the outer cover 26 andcan isolate the wearer's skin from liquid waste retained by theabsorbent body 40. In various embodiments, the body facing material 28can overlay a secondary liner 34. In such embodiments, the secondaryliner 34 can overlay the absorbent body 40. In various embodiments, afluid transfer layer 78 can be positioned between the secondary liner 34and the absorbent body 40. In various embodiments, an acquisition layer84 can be positioned between the secondary liner 34 and the absorbentbody 40 or a fluid transfer layer 78, if present. In variousembodiments, the secondary liner 34 can be bonded to the acquisitionlayer 84, or the fluid transfer layer 78 if no acquisition layer 84 ispresent, via adhesive and/or by a point fusion bonding. The point fusionbonding may be selected from ultrasonic, thermal, pressure bonding, andcombinations thereof.

In an embodiment, the secondary liner 34 can extend beyond the absorbentbody 40 and/or a fluid transfer layer 78, and/or an acquisition layer 84to overlay a portion of the outer cover 26 and can be bonded thereto byany method deemed suitable, such as, for example, by being bondedthereto by adhesive, to substantially enclose the absorbent body 40between the outer cover 26 and the secondary liner 34. The secondaryliner 34 may be narrower than the outer cover 26, but it is to beunderstood that the secondary liner 34 and the outer cover 26 may be ofthe same dimensions. It is also contemplated that the secondary liner 34may not extend beyond the absorbent body 40 and/or may not be secured tothe outer cover 26. The secondary liner 34 can be suitably compliant,soft feeling, and non-irritating to the wearer's skin and can be thesame as or less hydrophilic than the absorbent body 40 to permit bodyexudates to readily penetrate through to the absorbent body 40 andprovide a relatively dry surface to the wearer.

The secondary liner 34 can be manufactured from a wide selection ofmaterials, such as synthetic fibers (for example, polyester orpolypropylene fibers), natural fibers (for example, wood or cottonfibers), a combination of natural and synthetic fibers, porous foams,reticulated foams, apertured plastic films, or the like. Examples ofsuitable materials include, but are not limited to, rayon, wood, cotton,polyester, polypropylene, polyethylene, nylon, or other heat-bondablefibers, polyolefins, such as, but not limited to, copolymers ofpolypropylene and polyethylene, linear low-density polyethylene, andaliphatic esters such as polylactic acid, finely perforated film webs,net materials, and the like, as well as combinations thereof.

Various woven and non-woven fabrics can be used for the secondary liner34. The secondary liner 34 can include a woven fabric, a nonwovenfabric, a polymer film, a film-fabric laminate or the like, as well ascombinations thereof. Examples of a nonwoven fabric can include spunbondfabric, meltblown fabric, coform fabric, carded web, bonded-carded web,bicomponent spunbond fabric, spunlace, or the like, as well ascombinations thereof.

For example, the secondary liner 34 can be composed of a meltblown orspunbond web of polyolefin fibers. Alternatively, the secondary liner 34can be a bonded-carded web composed of natural and/or synthetic fibers.The secondary liner 34 can be composed of a substantially hydrophobicmaterial, and the hydrophobic material can, optionally, be treated witha surfactant or otherwise processed to impart a desired level ofwettability and hydrophilicity. The surfactant can be applied by anyconventional means, such as spraying, printing, brush coating or thelike. The surfactant can be applied to the entire secondary liner 34 orit can be selectively applied to particular sections of the secondaryliner 34. In an embodiment, the secondary liner 34 can be treated with amodifier which can increase the surface energy of the material surfaceor reduce the viscoelastic properties of body exudates, such as menses.

In an embodiment, a secondary liner 34 can be constructed of a non-wovenbicomponent web. The non-woven bicomponent web can be a spunbondedbicomponent web, or a bonded-carded bicomponent web. An example of abicomponent staple fiber includes a polyethylene/polypropylenebicomponent fiber. In this particular bicomponent fiber, thepolypropylene forms the core and the polyethylene forms the sheath ofthe fiber. Fibers having other orientations, such as multi-lobe,side-by-side, end-to-end may be used without departing from the scope ofthis disclosure. In an embodiment, a secondary liner 34 can be aspunbond substrate with a basis weight from about 10 or 12 to about 15or 20 gsm. In an embodiment, a secondary liner 34 can be a 12 gsmspunbond-meltblown-spunbond substrate having 10% meltblown contentapplied between the two spunbond layers.

Although the outer cover 26 and secondary liner 34 can includeelastomeric materials, it is contemplated that the outer cover 26 andthe secondary liner 34 can be composed of materials which are generallynon-elastomeric. In an embodiment, the secondary liner 34 can bestretchable, and more suitably elastic. In an embodiment, the secondaryliner 34 can be suitably stretchable and more suitably elastic in atleast the lateral or circumferential direction of the absorbent article10. In other aspects, the secondary liner 34 can be stretchable, andmore suitably elastic, in both the lateral and the longitudinaldirections.

Containment Flaps:

In an embodiment, containment flaps, 50 and 52, can be secured to thebody facing material 28 and/or, if present, the secondary liner 34, ofthe absorbent article 10 in a generally parallel, spaced relation witheach other laterally inward of the leg openings 56 to provide a barrieragainst the flow of body exudates to the leg openings 56. In anembodiment, the containment flaps, 50 and 52, can extend longitudinallyfrom the front waist region 12 of the absorbent article 10, through thecrotch region 16 to the back waist region 14 of the absorbent article10. The containment flaps, 50 and 52, can be bonded to the body facingmaterial 28 and/or the secondary liner 34 by a seam of adhesive 137 todefine a fixed proximal end 138 of the containment flaps, 50 and 52.

The containment flaps, 50 and 52, can be constructed of a fibrousmaterial which can be similar to the material forming the body facingmaterial 28 and/or the secondary liner 34, if present. Otherconventional material, such as polymer films, can also be employed. Eachcontainment flap, 50 and 52, can have a moveable distal end 136 whichcan include flap elastics, such as flap elastics 58 and 60,respectively. Suitable elastic materials for the flap elastic, 58 and60, can include sheets, strands or ribbons of natural rubber, syntheticrubber, or thermoplastic elastomeric materials.

The flap elastics, 58 and 60, as illustrated, can have two strands ofelastomeric material extending longitudinally along the distal ends 136of the containment flaps, 50 and 52, in generally parallel, spacedrelation with each other. The elastic strands can be within thecontainment flaps, 50 and 52, while in an elastically contractiblecondition such that contraction of the strands gathers and shortens thedistal ends 136 of the containment flaps, 50 and 52. As a result, theelastic strands can bias the distal ends 136 of each containment flap,50 and 52, toward a position spaced from the proximal end 138 of thecontainment flaps, 50 and 52, so that the containment flaps, 50 and 52,can extend away from the body facing material 28 and/or the secondaryliner 34 in a generally upright orientation of the containment flaps, 50and 52, especially in the crotch region 16 of the absorbent article 10,when the absorbent article 10 is fitted on the wearer. The distal end136 of the containment flaps, 50 and 52, can be connected to the flapelastics, 58 and 60, by partially doubling the containment flap, 50 and52, material back upon itself by an amount which can be sufficient toenclose the flap elastics, 58 and 60. It is to be understood, however,that the containment flaps, 50 and 52, can have any number of strands ofelastomeric material and may also be omitted from the absorbent article10 without departing from the scope of this disclosure.

Leg Elastics:

Leg elastic members, 66 and 68, can be secured between the outer andinner layers, 70 and 72, respectively, of the outer cover 26, such as bybeing bonded therebetween by laminate adhesive, generally adjacent thelateral outer edges of the inner layer 72 of the outer cover 26.Alternatively, the leg elastic members, 66 and 68, may be disposedbetween other layers of the absorbent article 10. A wide variety ofelastic materials may be used for the leg elastic members, 66 and 68.Suitable elastic materials can include sheets, strands or ribbons ofnatural rubber, synthetic rubber, or thermoplastic elastomericmaterials. The elastic materials can be stretched and secured to asubstrate, secured to a gathered substrate, or secured to a substrateand then elasticized or shrunk, for example, with the application ofheat, such that the elastic retractive forces are imparted to thesubstrate.

Fastening System:

In an embodiment, the absorbent article 10 can include a fastenersystem. The fastener system can include one or more back fasteners 140and one or more front fasteners 142. Portions of the fastener system maybe included in the front waist region 12, back waist region 14, or both.The fastener system can be configured to secure the absorbent article 10about the waist of the wearer and maintain the absorbent article 10 inplace during use. In an embodiment, the back fasteners 140 can includeone or more materials bonded together to form a composite ear as isknown in the art. For example, the composite fastener may be composed ofa stretch component 144, a nonwoven carrier or hook base 146, and afastening component 148.

Waist Elastic Members:

In an embodiment, the absorbent article 10 can have waist elasticmembers, 62 and 64, which can be formed of any suitable elasticmaterial. In such an embodiment, suitable elastic materials can include,but are not limited to, sheets, strands or ribbons of natural rubber,synthetic rubber, or thermoplastic elastomeric polymers. The elasticmaterials can be stretched and bonded to a substrate, bonded to agathered substrate, or bonded to a substrate and then elasticized orshrunk, for example, with the application of heat, such that elasticretractive forces are imparted to the substrate. It is to be understood,however, that the waist elastic members, 62 and 64, may be omitted fromthe absorbent article 10 without departing from the scope of thisdisclosure.

Side Panels:

In an embodiment in which the absorbent article 10 can be a trainingpant, youth pant, diaper pant, or adult absorbent pant, the absorbentarticle 10 may have front side panels, 182 and 184, and rear sidepanels, 186 and 188. FIG. 18 provides a non-limiting illustration of anabsorbent article 10 that can have side panels, such as front sidepanels, 182 and 184, and rear side panels, 186 and 188. The front sidepanels 182 and 184 and the rear side panels 186 and 188 of the absorbentarticle 10 can be bonded to the absorbent article 10 in the respectivefront and back waist regions, 12 and 14, and can extend outwardly beyondthe longitudinal side edges, 18 and 20, of the absorbent article 10. Inan example, the front side panels, 182 and 184, can be bonded to theinner layer 72 of the outer cover 26, such as being bonded thereto byadhesive, by pressure bonding, by thermal bonding or by ultrasonicbonding. These front side panels, 182 and 184, may also be bonded to theouter layer 70 of the outer cover 26, such as by being bonded thereto byadhesive, by pressure bonding, by thermal bonding, or by ultrasonicbonding. The back side panels, 186 and 188, may be secured to the outerand inner layers, 70 and 72 respectively, of the outer cover 26 at theback waist region 14 of the absorbent article 10 in substantially thesame manner as the front side panels, 182 and 184. Alternatively, thefront side panels, 182 and 184, and the back side panels, 186 and 188,may be formed integrally with the absorbent article 10, such as by beingformed integrally with the outer cover 26, the body facing material 28,the secondary liner 34 or other layers of the absorbent article 10.

For improved fit and appearance, the front side panels, 182 and 184, andthe back side panels, 186 and 188, can suitably have an average lengthmeasured parallel to the longitudinal axis of the absorbent article 10that is about 20 percent or greater, and more suitably about 25 percentor greater, of the overall length of the absorbent article 10, alsomeasured parallel to the longitudinal axis. For example, absorbentarticles 10 having an overall length of about 54 centimeters, the frontside panels, 182 and 184, and the back side panels, 186 and 188,suitably have an average length of about 10 centimeters or greater, andmore suitably have an average length of about 15 centimeters.

Each of the front side panels, 182 and 184, and back side panels, 186and 188, can be constructed of one or more individual, distinct piecesof material. For example, each front side panel, 182 and 184, and backside panel, 186 and 188, can include first and second side panelportions (not shown) joined at a seam (not shown), with at least one ofthe portions including an elastomeric material. Alternatively, eachindividual front side panel, 182 and 184, and back side panel, 186 and188, can be constructed of a single piece of material folded over uponitself along an intermediate fold line (not shown).

The front side panels, 182 and 184, and back side panels, 186 and 188,can each have an outer edge 190 spaced laterally from the engagementseam 192, a leg end edge 194 disposed toward the longitudinal center ofthe absorbent article 10, and a waist end edge 196 disposed toward alongitudinal end of the absorbent article 10. The leg end edge 194 andwaist end edge 196 can extend from the longitudinal side edges, 18 and20, of the absorbent article 10 to the outer edges 190. The leg endedges 194 of the front side panels, 182 and 184, and back side panels,186 and 188, can form part of the longitudinal side edges, 18 and 20, ofthe absorbent article 10. The leg end edges 194 of the illustratedabsorbent article 10 can be curved and/or angled relative to thetransverse axis to provide a better fit around the wearer's legs.However, it is understood that only one of the leg end edges 194 can becurved or angled, such as the leg end edge 194 of the back waist region14, or neither of the leg end edges 194 can be curved or angled, withoutdeparting from the scope of this disclosure. The waist end edges 196 canbe parallel to the transverse axis. The waist end edges 196 of the frontside panels, 182 and 184, can form part of the front waist edge 22 ofthe absorbent article 10, and the waist end edges 196 of the back sidepanels, 186 and 188, can form part of the back waist edge 24 of theabsorbent article 10.

The front side panels, 182 and 184, and back side panels, 186 and 188,can include an elastic material capable of stretching laterally.Suitable elastic materials, as well as one described process forincorporating elastic front side panels, 182 and 184, and back sidepanels, 186 and 188, into an absorbent article 10 are described in thefollowing U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel etal., U.S. Pat. No. 5,224,405 issued Jul. 6, 1993 to Pohjola, U.S. Pat.No. 5,104,116 issued Apr. 14, 1992 to Pohjola, and U.S. Pat. No.5,046,272 issued Sep. 10, 1991 to Vogt et al.; all of which areincorporated herein by reference. As an example, suitable elasticmaterials include a stretch-thermal laminate (STL), a neck-bondedlaminate (NBL), a reversibly necked laminate, or a stretch-bondedlaminate (SBL) material. Methods of making such materials are well knownto those skilled in the art and described in U.S. Pat. No. 4,663,220issued May 5, 1987 to Wisneski et al., U.S. Pat. No. 5,226,992 issuedJul. 13, 1993 to Morman, and European Patent Application No. EP 0 217032 published on Apr. 8, 1987, in the names of Taylor et al., and PCTApplication WO 01/88245 in the name of Welch et al., all of which areincorporated herein by reference. Other suitable materials are describedin U.S. patent application Ser. No. 12/649,508 to Welch et al. and Ser.No. 12/023,447 to Lake et al., all of which are incorporated herein byreference. Alternatively, the front side panels, 182 and 184, and backside panels, 186 and 188, may include other woven or non-wovenmaterials, such as those described above as being suitable for the outercover 26 or secondary liner 34, mechanically pre-strained composites, orstretchable but inelastic materials.

Feminine Hygiene Product:

FIG. 19 provides a non-limiting illustration of an absorbent article 10in the form of a feminine hygiene product such as a menstrual pad orfeminine adult incontinence product. The absorbent article 10 can have alengthwise, longitudinal direction 30 which can extend along anappointed x-axis of the absorbent article 10, and a transverse, lateraldirection 32 which can extend along an appointed y-axis of the absorbentarticle 10. Additionally, the absorbent article 10 can include first andsecond longitudinally opposed end portions, 13 and 15, and anintermediate region 17 located between the end portions, 13 and 15. Theabsorbent article 10 can have first and second longitudinal side edges,18 and 20, which can be the longitudinal sides of the elongatedabsorbent article 10. The longitudinal side edges, 18 and 20, can becontoured to match the shape of the absorbent article 10. The absorbentarticle 10 can have any desired shape such as, for example, a dog boneshape, a race track shape, an hourglass shape, or the like.Additionally, the absorbent article 10 can be substantiallylongitudinally symmetric, or may be longitudinally asymmetric, asdesired.

As representatively shown, the longitudinal dimension of the absorbentarticle 10 can be relatively larger than the transverse lateraldimension of the absorbent article 10. Configurations of the absorbentarticle 10 can include a body facing material 28 and an outer cover 26,such as described herein. An absorbent body 40, such as describedherein, can be positioned between the body facing material 28 and theouter cover 26. As representatively shown, for example, the peripheriesof the body facing material 28 and the outer cover 26 can besubstantially entirely coterminous or the peripheries of the body facingmaterial 28 and the outer cover 26 can be partially or entirelynon-coterminous. In an embodiment, the absorbent article 10 can includea secondary liner 34 such as described herein. In an embodiment, theabsorbent article 10 can include an acquisition layer 84 such asdescribed herein.

In an embodiment in which the absorbent article 10 can be a femininehygiene product, the absorbent article 10 can include laterallyextending wing portions 198 that can be integrally connected to the sideedges, 18 and 20, of the absorbent article 10 in the intermediate region17 of the absorbent article 10. For example, the wing portions 198 maybe separately provided members that are subsequently attached orotherwise operatively joined to the intermediate region 17 of theabsorbent article 10. In other configurations, the wing portions 198 maybe unitarily formed with one or more components of the absorbent article10. As an example, a wing portion 198 may be formed from acorresponding, operative extension of the body facing material 28, asecondary liner 34, if present, an outer cover 26, and combinationsthereof.

The wing portions 198 can have an appointed storage position (not shown)in which the wing portions 198 are directed generally inwardly towardthe longitudinally extending centerline 31. In various embodiments, thewing portion 198 that is connected to one side edge, such as side edge18, may have sufficient cross-directional length to extend and continuepast the centerline 31 to approach the laterally opposite side edge 20of the absorbent article 10. The storage position of the wing portions198 can ordinarily represent an arrangement observed when the absorbentarticle 10 is first removed from a wrapper or packaging. Prior toplacing the absorbent article 10, such as the feminine hygiene product,into a bodyside of an undergarment prior to use, the wing portions 198can be selectively arranged to extend laterally from the side edges, 18and 20, of the absorbent article 10 intermediate region 17. Afterplacing the absorbent article 10 into the undergarment, the wingportions 198 can be operatively wrapped and secured around the sideedges of the undergarment to help hold the absorbent article 10 inplace, in a manner well known in the art.

The wing portions 198 can have any operative construction and caninclude a layer of any operative material. Additionally, each wingportion 198 can comprise a composite material. For example, the wingportions 198 can include a spunbond fabric material, a bicomponentspunbond material, a necked spunbond material, a neck-stretched-bondedlaminate (NBL) material, a meltblown fabric material, a bonded cardedweb, a thermal bonded carded web, a through-air bonded carded web, orthe like, as well as combinations thereof.

Each wing portion 198 can include a panel-fastener component (not shown)which can be operatively joined to an appointed engagement surface ofits associated wing portion 198. The panel-fastener component caninclude a system of interengaging mechanical fasteners, a system ofadhesive fasteners, or the like, as well as combinations thereof. In anembodiment, either or both wing portions 198 can include apanel-fastener system which incorporates an operative adhesive. Theadhesive may be a solvent based adhesive, a hot melt adhesive, apressure-sensitive adhesive, or the like, as well as combinationsthereof.

In an embodiment, a garment attachment mechanism (not shown), such as agarment attachment adhesive, can be distributed onto the garment side ofthe absorbent article 10. In an embodiment, the garment adhesive can bedistributed over the garment side of the absorbent article 10 of theouter cover 26, and one or more layers or sheets of release material canbe removably placed over the garment adhesive for storage prior to use.In an embodiment, the garment attachment mechanism can include anoperative component of a mechanical fastening system. In such anembodiment, the garment attachment mechanism can include an operativecomponent of a hook-and-loop type of fastening system.

Decolorizing Composition:

In an embodiment, a chemical treatment may be employed to alter thecolor of bodily exudates captured by the absorbent article 10. In anembodiment, for example, the treatment may be a decolorizing compositionthat agglutinates (agglomerates) red blood cells in blood and menses andlimits the extent that the red color of menses is visible. One suchcomposition includes a surfactant, such as described in U.S. Pat. No.6,350,711 to Potts, et al., which is incorporated herein in its entiretyby reference thereto. Non-limiting examples of such surfactants includePluronic® surfactants (tri-block copolymer surfactant), inorganic saltsthat contain a polyvalent anion (e.g., divalent, trivalent, etc.), suchas sulfate (SO₄ ²⁻), phosphate (PO₄ ³⁻), carbonate (CO₃ ²⁻), oxide(O²⁻), etc., and a monovalent cation, such as sodium (Na⁺), potassium(K⁺), lithium (Li⁺), ammonium (NH₄ ⁺), etc. Alkali metal cations arealso beneficial. Some examples of salts formed from such ions include,but are not limited to, disodium sulfate (Na₂SO₄), dipotassium sulfate(K₂SO₄), disodium carbonate (Na₂CO₃), dipotassium carbonate (K₂CO₃),monosodium phosphate (NaH₂PO₄), disodium phosphate (Na₂HPO₄),monopotassium phosphate (KH₂PO₄), dipotassium phosphate (K₂HPO₄), etc.Mixtures of the aforementioned salts may also be effective infacilitating physical separation of red blood cells. For example, amixture of disodium sulfate (Na₂SO₄) and monopotassium phosphate(KH₂PO₄) may be employed.

Besides agglutinating agents, the decolorizing composition may alter thechemical structure of hemoglobin to change its color. Examples of suchcompositions are described in U.S. Patent Application Publication No.2009/0062764 to MacDonald, et al., which is incorporated herein in itsentirety by reference thereto. In an embodiment, the composition caninclude an oxidizing agent that can be generally capable of oxidizinghemoglobin or other substances responsible for unwanted color of thebodily exudates. Some examples of oxidizing agents include, but are notlimited to, peroxygen bleaches (e.g., hydrogen peroxide, percarbonates,persulphates, perborates, peroxyacids, alkyl hydroperoxides, peroxides,diacyl peroxides, ozonides, supereoxides, oxo-ozonides, and periodates);hydroperoxides (e.g., tert-butyl hydroperoxide, cumyl hydroperoxide,2,4,4-trimethylpentyl-2-hydroperoxide,di-isopropylbenzene-monohydroperoxide, tert-amyl hydroperoxide and2,5-dimethyl-hexane-2,5-dihydroperoxide); peroxides (e.g., lithiumperoxide, sodium peroxide, potassium peroxide, ammonium peroxide,calcium peroxide, rubidium peroxide, cesium peroxide, strontiumperoxide, barium peroxide, magnesium peroxide, mercury peroxide, silverperoxide, zirconium peroxide, hafnium peroxide, titanium peroxide,phosphorus peroxide, sulphur peroxide, rhenium peroxide, iron peroxide,cobalt peroxide, and nickel peroxide); perborates (e.g., sodiumperborate, potassium perborate, and ammonium perborate); persulphates(e.g., sodium persulphate, potassium dipersulphate, and potassiumpersulphate); and so forth. Other suitable oxidizing agents include, butare not limited to omega-3 and -6 fatty acids, such as linoleic acids,α-linoleic acid, arachidonic acid, eicosapentaenoic acid,docosahexaenoic acid, eicosadienoic acid, eicosatrienoic acid, etc.

The decolorizing composition may be applied to any liquid permeablelayer of the absorbent article 10 where it can contact aqueous fluidsexuded by the body, such as, for example, menses, such as the bodyfacing layer 28, secondary liner 34, acquisition layer 84, fluidtransfer layer 78, absorbent body 40, outer cover 26, and combinationsthereof. In an embodiment, the decolorizing composition may be appliedto only a portion of the surface of the layer(s) to which it is appliedto ensure that the layer(s) is still capable of retaining sufficientabsorbent properties. In an embodiment, it may be desired that thedecolorizing composition is positioned closer to the absorbent body 40.In an embodiment, an additional layer (not shown) may be employed in theabsorbent article 10 and may be applied with the decolorizingcomposition that is in contact with the absorbent body 40. Theadditional layer may be formed from a variety of different porousmaterials, such as a perforated film, nonwoven web (e.g., cellulosicweb, spunbond web, meltblown web, etc.), foams, etc. In an embodiment,the additional layer may be in the form of a hollow enclosure (e.g.,sachet, bag, etc.) that is folded so that it partially or completelysurrounds the absorbent body 40. The decolorizing composition may bedisposed within this enclosure so that it remains sealed therein priorto use.

Non-Limiting Examples of Embodiments of Absorbent Articles

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, and a body facing material 28. In such an embodiment,the body facing material 28 can have a support layer 92 and a projectionlayer 94. In such an embodiment, the projection layer 94 can have aninner 102 and an outer 104 surface and can have a plurality of hollowprojections 90 extending from the outer surface 104 of the projectionlayer 94. In various embodiments, the body facing material 28 of theabsorbent article 10 can further include a land area 116 with greaterthan about 1% open area within a chosen area of the body facing material28, projections 90 with less than about 1% open area within a chosenarea of the body facing material 28, a plurality of fibers of theprojection layer 94 entangled with the support layer 92, a load of morethan about 2 Newtons per 25 mm width at 10% extension in the machinedirection, projections 90 having a height greater than about 1 mm, aresiliency of greater than about 70%, and combinations thereof. Invarious embodiments, the absorbent article 10 can further include asecondary liner 34 positioned between the body facing material 28 andthe absorbent body 40. In various embodiments, the absorbent body 40 canbe free from superabsorbent material. In various embodiments, theabsorbent body 40 can have greater than about 15% superabsorbentmaterial. In various embodiments, the open area of the projections 90can be due to interstitial fiber-to-fiber spacing. In variousembodiments, the open area of the land area 116 can be due tointerstitial fiber-to-fiber spacing.

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, a body facing material 28 and a secondary liner 34positioned between the body facing material 28 and the absorbent body40. In such an embodiment, body facing material 28 can have a supportlayer 92 and a projection layer 94. In such an embodiment, theprojection layer 94 can have an inner 102 and an outer 104 surface andcan have a plurality of hollow projections 90 extending from the outersurface 104 of the projection layer 94. In various embodiments, the bodyfacing material 28 of the absorbent article 10 can further include aland area 116 with greater than about 1% open area within a chosen areaof the body facing material 28, projections 90 with less than about 1%open area within a chosen area of the body facing material 28, aplurality of fibers of the projection layer 94 entangled with thesupport layer 92, a load of more than about 2 Newtons per 25 mm width at10% extension in the machine direction, projections 90 having a heightgreater than about 1 mm, a resiliency of greater than about 70%, andcombinations thereof. In various embodiments, the absorbent body 40 canbe free from superabsorbent material. In various embodiments, theabsorbent body 40 can have greater than about 15% superabsorbentmaterial. In various embodiments, the open area of the projections 90can be due to interstitial fiber-to-fiber spacing. In variousembodiments, the open area of the land areas 116 can be due tointerstitial fiber-to-fiber spacing.

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, and a body facing material 28. In such an embodiment,the body facing material 28 can have a support layer 92 and a projectionlayer 94. In such an embodiment, the projection layer 94 can have aninner 102 and an outer 104 surface and can have a plurality of hollowprojections 90 extending from the outer surface 104 of the projectionlayer 94. In such an embodiment, the body facing material 28 can furtherhave a load of more than about 2 Newtons per 25 mm width at 10%extension in the machine direction. In various embodiments, the bodyfacing material 28 of the absorbent article 10 can further include aland area 116 with greater than about 1% open area within a chosen areaof the body facing material 28, projections with less than about 1% openarea within a chosen area of the body facing material 28, a plurality offibers of the projection layer 94 entangled with the support layer 92,projections 90 having a height greater than about 1 mm, a resiliency ofgreater than about 70%, and combinations thereof. In variousembodiments, the absorbent article 10 can further include a secondaryliner 34 positioned between the body facing material 28 and theabsorbent body 40. In various embodiments, the absorbent body 40 can befree from superabsorbent material. In various embodiments, the absorbentbody 40 can have greater than about 15% superabsorbent material. Invarious embodiments, the open area of the projections 90 can be due tointerstitial fiber-to-fiber spacing. In various embodiments, the openarea of the land areas 116 can be due to interstitial fiber-to-fiberspacing.

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, and a body facing material 28. In such an embodiment,the body facing material 28 can have a support layer 92 and a projectionlayer 94. In such an embodiment, the projection layer 94 can have aninner 102 and an outer 104 surface and can have a plurality of hollowprojections 90 extending from the outer surface 104 of the projectionlayer 94. In such an embodiment, the body facing material 28 can have aresiliency greater than about 70%. In various embodiments, the bodyfacing material 28 of the absorbent article 10 can further include aland area 116 with greater than about 1% open area within a chosen areaof the body facing material 28, projections with less than about 1% openarea within a chosen area of the body facing material 28, a plurality offibers of the projection layer 94 entangled with the support layer 92, aload of more than about 2 Newtons per 25 mm width at 10% extension inthe machine direction, projections 90 having a height greater than about1 mm, and combinations thereof. In various embodiments, the absorbentarticle 10 can further include a secondary liner 34 positioned betweenthe body facing material 28 and the absorbent body 40. In variousembodiments, the absorbent body 40 can be free from superabsorbentmaterial. In various embodiments, the absorbent body 40 can have greaterthan about 15% superabsorbent material. In various embodiments, the openarea of the projections 90 can be due to interstitial fiber-to-fiberspacing. In various embodiments, the open area of the land areas 116 canbe due to interstitial fiber-to-fiber spacing.

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, and a body facing material 28 which can have asupport layer 92 and a projection layer 94. The projection layer 94 canhave an inner 102 and an outer 104 surface and can have a plurality ofhollow projections 90 extending from the outer surface 104 of theprojection layer 94. In such an embodiment, the body facing material 28can have a land area 116 which can have greater than about 1% open areawithin a chosen area of the body facing material 28 and projections 90having less than about 1% open area within a chosen area of the bodyfacing material 28. In various embodiments, the body facing material 28of the absorbent article 10 can further include a plurality of fibers ofthe projection layer 94 entangled with the support layer 92, a load ofmore than about 2 Newtons per 25 mm width at 10% extension in themachine direction, projections 90 having a height greater than about 1mm, a resiliency of greater than about 70%, and combinations thereof. Invarious embodiments, the absorbent article 10 can further include asecondary liner 34 positioned between the body facing material 28 andthe absorbent body 40. In various embodiments, the absorbent body 40 canbe free from superabsorbent material. In various embodiments, theabsorbent body 40 can have greater than about 15% superabsorbentmaterial. In various embodiments, the open area of the projections 90can be due to interstitial fiber-to-fiber spacing. In variousembodiments, the open area of the land areas 116 can be due tointerstitial fiber-to-fiber spacing. In various embodiments, the amountof residual fecal material simulant remaining on the body facingmaterial 28 following insult with fecal material simulant according tothe test method described herein is less than about 2.5 grams.

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, a body facing material 28, and a fluid transfer layer78 positioned between the absorbent body 40 and the body facing material28. In such an embodiment, the body facing material 28 can have asupport layer 92 and a projection layer 94. In such an embodiment, theprojection layer 94 can have an inner 102 and an outer 104 surface andcan have a plurality of hollow projections 90 extending from the outersurface 104 of the projection layer 94. In various embodiments, thefluid transfer layer can contain a polymeric material. In variousembodiments, the body facing material 28 of the absorbent article 10 canfurther include a land area 116 with greater than about 1% open areawithin a chosen area of the body facing material 28, projections 90having less than about 1% open area within a chosen area of the bodyfacing material 28, a plurality of fibers of the projection layer 94entangled with the support layer 92, a load of more than about 2 Newtonsper 25 mm width at 10% extension in the machine direction, projections90 having a height greater than about 1 mm, a resiliency of greater thanabout 70%, and combinations thereof. In various embodiments, theabsorbent body 40 can be free from superabsorbent material. In variousembodiments, the absorbent body 40 can have greater than about 15%superabsorbent material. In various embodiments, the open area of theprojections 90 can be due to interstitial fiber-to-fiber spacing. Invarious embodiments, the open area of the land areas 116 can be due tointerstitial fiber-to-fiber spacing. In various embodiments, the amountof residual fecal material simulant remaining on the body facingmaterial 28 following insult with fecal material simulant according tothe test method described herein is less than about 2.5 grams.

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, a body facing material 28, an acquisition layer 84positioned between the absorbent body 40 and the body facing material28, and a fluid transfer layer 78 positioned between the acquisitionlayer 84 and the absorbent body 40. In such an embodiment, the bodyfacing material 28 can have a support layer 92 and a projection layer94. In such an embodiment, the projection layer 94 can have an inner 102and an outer 104 surface and can have a plurality of hollow projections90 extending from the outer surface 104 of the projection layer 94. Invarious embodiments, the acquisition layer 84 can have fibers with adenier less than about 5. In various embodiments, the fluid transferlayer 78 can contain a cellulosic material. In various embodiments, thebody facing material 28 of the absorbent article 10 can further includea land area 116 with greater than about 1% open area within a chosenarea of the body facing material 28, projections 90 having less thanabout 1% open area within a chosen area of the body facing material 28,a plurality of fibers of the projection layer 94 entangled with thesupport layer 92, a load of more than about 2 Newtons per 25 mm width at10% extension in the machine direction, projections 90 having a heightgreater than about 1 mm, a resiliency of greater than about 70%, andcombinations thereof. In various embodiments, the absorbent body 40 canbe free from superabsorbent material. In various embodiments, theabsorbent body 40 can have greater than about 15% superabsorbentmaterial. In various embodiments, the open area of the projections 90can be due to interstitial fiber-to-fiber spacing. In variousembodiments, the open area of the land areas 116 can be due tointerstitial fiber-to-fiber spacing. In various embodiments, the amountof residual fecal material simulant remaining on the body facingmaterial 28 following insult with fecal material simulant according tothe test method described herein is less than about 2.5 grams.

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, a body facing material 28 which can have a supportlayer 92 and a projection layer 94, and a fluid transfer layer 78positioned between the absorbent body 40 and the body facing material28. The projection layer 94 can have an inner 102 and an outer 104surface and can have a plurality of hollow projections 90 extending fromthe outer surface 104 of the projection layer 94. In such an embodiment,the body facing material 28 can have a land area 116 which can havegreater than about 10% open area within a chosen area of the body facingmaterial 28 and projections 90 having less than about 1% open areawithin a chosen area of the body facing material 28. In variousembodiments, the body facing material 28 of the absorbent article 10 canfurther include a plurality of fibers of the projection layer 94entangled with the support layer 92, a load of more than about 2 Newtonsper 25 mm width at 10% extension in the machine direction, projections90 having a height greater than about 1 mm, a resiliency of greater thanabout 70%, and combinations thereof. In various embodiments, theabsorbent body 40 can be free from superabsorbent material. In variousembodiments, the absorbent body 40 can have greater than about 15%superabsorbent material. In various embodiments, the open area of theprojections 90 can be due to interstitial fiber-to-fiber spacing. Invarious embodiments, the open area of the land areas 116 can be due tointerstitial fiber-to-fiber spacing. In various embodiments, the amountof residual fecal material simulant remaining on the body facingmaterial 28 following insult with fecal material simulant according tothe test method described herein is less than about 2.5 grams.

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, a body facing material 28, an acquisition layer 84positioned between the absorbent body 40 and the body facing material28, and a fluid transfer layer 78 positioned between the acquisitionlayer 84 and the absorbent body 40. In such an embodiment, the fluidtransfer layer 78 can include a polymeric material. In such anembodiment, the body facing material 28 can have a support layer 92 anda projection layer 94. In such an embodiment, the projection layer 94can have an inner 102 and an outer 104 surface and can have a pluralityof hollow projections 90 extending from the outer surface 104 of theprojection layer 94. In various embodiments, the acquisition layer 84can have fibers with a denier greater than about 5. In variousembodiments, the body facing material 28 of the absorbent article 10 canfurther include a land area 116 with greater than about 1% open areawithin a chosen area of the body facing material 28, projections 90having less than about 1% open area within a chosen area of the bodyfacing material 28, a plurality of fibers of the projection layer 94entangled with the support layer 92, a load of more than about 2 Newtonsper 25 mm width at 10% extension in the machine direction, projections90 having a height greater than about 1 mm, a resiliency of greater thanabout 70%, and combinations thereof. In various embodiments, theabsorbent body 40 can be free from superabsorbent material. In variousembodiments, the absorbent body 40 can have greater than about 15%superabsorbent material. In various embodiments, the open area of theprojections 90 can be due to interstitial fiber-to-fiber spacing. Invarious embodiments, the open area of the land areas 116 can be due tointerstitial fiber-to-fiber spacing. In various embodiments, the area ofspread of fecal material simulant on the body facing material 28following insult with fecal material simulant according to the testmethod described herein can be less than about 34 cm².

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, a body facing material 28 with a land area 116 havinggreater than about 5% open area within a chosen area of the body facingmaterial 28, an acquisition layer 84 positioned between the absorbentbody 40 and the body facing material 28, and a fluid transfer layer 78positioned between the acquisition layer 84 and the absorbent body 40.In such an embodiment, the fluid transfer layer 78 can contain acellulosic material. In such an embodiment, the body facing material 28can have a support layer 92 and a projection layer 94. In such anembodiment, the projection layer 94 can have an inner 102 and an outer104 surface and can have a plurality of hollow projections 90 extendingfrom the outer surface 104 of the projection layer 94 wherein theprojections have less than about 1% open area within a chosen area ofthe body facing material. In various embodiments, the acquisition layer84 can have fibers with a denier greater than about 5. In variousembodiments, the acquisition layer 84 can have fibers with a denier lessthan about 5. In various embodiments, the body facing material 28 of theabsorbent article 10 can further include a plurality of fibers of theprojection layer 94 entangled with the support layer 92, a load of morethan about 2 Newtons per 25 mm width at 10% extension in the machinedirection, projections 90 having a height greater than about 1 mm, aresiliency of greater than about 70%, and combinations thereof. Invarious embodiments, the absorbent body 40 can be free fromsuperabsorbent material. In various embodiments, the absorbent body 40can have greater than about 15% superabsorbent material. In variousembodiments, the open area of the projections 90 can be due tointerstitial fiber-to-fiber spacing. In various embodiments, the openarea of the land area 116 can be due to interstitial fiber-to-fiberspacing. In various embodiments, the area of spread of fecal materialsimulant on the body facing material 28 following insult with fecalmaterial simulant according to the test method described herein can beless than about 34 cm².

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, a body facing material 28, an acquisition layer 84positioned between the absorbent body 40 and the body facing material28, and a fluid transfer layer 78 positioned between the acquisitionlayer 84 and the absorbent body 40. In such an embodiment, the fluidtransfer layer 78 can contain a cellulosic material. In such anembodiment, the body facing material 28 can have a support layer 92 anda projection layer 94. In such an embodiment, the projection layer 94can have an inner 102 and an outer 104 surface and can have a pluralityof hollow projections 90 extending from the outer surface 104 of theprojection layer 94. In various embodiments, the acquisition layer 84can have fibers with a denier greater than about 5. In variousembodiments, the acquisition layer 84 can have fibers with a denier lessthan about 5. In various embodiments, the body facing material 28 of theabsorbent article 10 can further include a plurality of fibers of theprojection layer 94 entangled with the support layer 92, a load of morethan about 2 Newtons per 25 mm width at 10% extension in the machinedirection, projections 90 having a height greater than about 1 mm,projections having less than about 1% open area within a chosen area ofthe body facing material 28, a resiliency of greater than about 70%, andcombinations thereof. In various embodiments, the body facing material28 can have a land area 116 and the land area 116 can have an open areagreater than about 1% within a chosen area of the body facing material28. In various embodiments, the absorbent body 40 can be free fromsuperabsorbent material. In various embodiments, the absorbent body 40can have greater than about 15% superabsorbent material. In variousembodiments, the open area of the projections 90 is due to interstitialfiber-to-fiber spacing. In various embodiments, the open area of theland areas 116 is due to interstitial fiber-to-fiber spacing. In variousembodiments, the area of spread of fecal material simulant on the bodyfacing material 28 following insult with fecal material simulantaccording to the test method described herein can be less than about 34cm².

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, and a body facing material 28. In such an embodiment,the body facing material 28 can have a support layer 92 and a projectionlayer 94. In such an embodiment, the projection layer 94 can have aninner 102 and an outer 104 surface and can have a plurality of hollowprojections 90 extending from the outer surface 104 of the projectionlayer 94. In such an embodiment, the absorbent article 10 can have asecond intake time of simulated menses through the body facing material28 of less than about 30 seconds following insult with simulated mensesaccording to the Intake/Rewet test method described herein. In variousembodiments, the body facing material 28 can further include a land area116 with greater than about 1% open area within a chosen area of thebody facing material 28, projections 90 with less than about 1% openarea within a chosen area of the body facing material 28, a plurality offibers of the projection layer 94 entangled with the support layer 92, aload of more than about 2 Newtons per 25 mm width at 10% extension inthe machine direction, projections 90 having a height greater than about1 mm, a resiliency of greater than about 70% and combinations thereof.In various embodiments, the absorbent article 10 can further include asecondary liner 34 positioned between the body facing material 28 andthe absorbent body 40. In various embodiments, the absorbent body 40 canbe free from superabsorbent material. In various embodiments, theabsorbent body 40 can have greater than about 15% superabsorbentmaterial. In various embodiments, the open area of the land area 116 canbe due to interstitial fiber-to-fiber spacing.

In an embodiment, an absorbent article 10 can have an outer cover 26, anabsorbent body 40, a body facing material 28, and a secondary liner 34positioned between the body facing material 28 and the absorbent body40. In such an embodiment, the body facing material 28 can have asupport layer 92 and a projection layer 94. In such an embodiment, theprojection layer 94 can have an inner 102 and an outer 104 surface andcan have a plurality of hollow projections 90 extending from the outersurface 104 of the projection layer 94. In such an embodiment, theabsorbent article 10 can have a second intake time of simulated mensesthrough the body facing material 28 of less than about 30 secondsfollowing insult with simulated menses according to the Intake/Rewettest method described herein. In various embodiments, the body facingmaterial 28 can further include a land area 116 with greater than about1% open area within a chosen area of the body facing material 28,projections 90 with less than about 1% open area within a chosen area ofthe body facing material 28, a plurality of fibers of the projectionlayer 94 entangled with the support layer 92, a load of more than about2 Newtons per 25 mm width at 10% extension in the machine direction,projections 90 having a height greater than about 1 mm, a resiliency ofgreater than about 70% and combinations thereof. In various embodiments,the absorbent body 40 can be free from superabsorbent material. Invarious embodiments, the absorbent body 40 can have greater than about15% superabsorbent material. In various embodiments, the open area ofthe land area 116 can be due to interstitial fiber-to-fiber spacing.

Method to Determine Percent Open Area

The percentage of open area can be determined by using the imageanalysis measurement method described herein. In this context, the openarea is considered the regions within a material where light transmittedfrom a light source passes directly thru those regions unhindered in thematerial of interest. Generally, the image analysis method determines anumeric value of percent open area for a material via specific imageanalysis measurement parameters such as area. The percent open areamethod is performed using conventional optical image analysis techniquesto detect open area regions in both land areas and projectionsseparately and then calculating their percentages in each. To separateland areas and projections for subsequent detection and measurement,incident lighting is used along with image processing steps. An imageanalysis system, controlled by an algorithm, performs detection, imageprocessing and measurement and also transmits data digitally to aspreadsheet database. The resulting measurement data are used todetermine the percent open area of materials possessing land areas andprojections.

The method for determining the percent open area in both land areas andprojections of a given material includes the step of acquiring twoseparate digital images of the material. An exemplary setup foracquiring the image is representatively illustrated in FIG. 20.Specifically, a CCD video camera 200 (e.g., a Leica DFC 310 FX videocamera operated in gray scale mode and available from Leica Microsystemsof Heerbrugg, Switzerland) is mounted on a standard support 202 such asa Polaroid MP-4 Land Camera standard support or equivalent availablefrom Polaroid Resource Center in Cambridge, Miss. The standard support202 is attached to a macro-viewer 204 such as a KREONITE macro-vieweravailable from Dunning Photo Equipment, Inc., having an office in Bixby,Okla. An auto stage 208 is placed on the upper surface 206 of themacro-viewer 204. The auto stage 208 is used to automatically move theposition of a given material for viewing by the camera 200. A suitableauto stage is Model H112, available from Prior Scientific Inc., havingan office in Rockland, Mass.

The material possessing land areas and projections is placed on the autostage 208 under the optical axis of a 60 mm Nikon AF Micro Nikkor lens210 with an f-stop setting of 4. The Nikon lens 210 is attached to theLeica DFC 310 FX camera 200 using a c-mount adaptor. The distance D1from the front face 212 of the Nikon lens 210 to the material is 21 cm.The material is laid flat on the auto stage 208 and any wrinkles removedby gentle stretching and/or fastening it to the auto stage 208 surfaceusing transparent adhesive tape at its outer edges. The material isoriented so the machine-direction (MD) runs in the horizontal directionof the resulting image. The material surface is illuminated withincident fluorescent lighting provided by a 16 inch diameter, 40 watt,GE Circline fluorescent lamp 214. The lamp 214 is contained in a fixturethat is positioned so it is centered over the material and under thevideo camera above and is a distance D2 of 3 inches above the materialsurface. The illumination level of the lamp 214 is controlled with aVariable Auto-transformer, type 3PN1010, available from Staco EnergyProducts Co. having an office in Dayton, Ohio. Transmitted light is alsoprovided to the material from beneath the auto stage 208 by a bank offive 20 watt fluorescent lights 218 covered with a diffusing plate 220.The diffusing plate 220 is inset into, and forms a portion of, the uppersurface 206 of the macro-viewer 204. The diffusing plate 220 is overlaidwith a black mask 222 possessing a 3-inch by 3-inch opening 224. Theopening 224 is positioned so that it is centered under the optical axisof the Leica camera and lens system. The distance D3 from the opening224 to the surface of the auto stage 208 is approximately 17 cm. Theillumination level of the fluorescent light bank 218 is also controlledwith a separate Variable Auto-transformer.

The image analysis software platform used to perform the percent openarea measurements is a QWIN Pro (Version 3.5.1) available from LeicaMicrosystems, having an office in Heerbrugg, Switzerland. The system andimages are also calibrated using the QWIN software and a standard rulerwith metric markings at least as small as one millimeter. Thecalibration is performed in the horizontal dimension of the video cameraimage. Units of millimeters per pixel are used for the calibration.

The method for determining the percent open area of a given materialincludes the step of performing several area measurements from bothincident and transmitted light images. Specifically, an image analysisalgorithm is used to acquire and process images as well as performmeasurements using Quantimet User Interactive Programming System (QUIPS)language. The image analysis algorithm is reproduced below.

NAME = % Open Area - Land vs Projection Regions-1 PURPOSE = Measures %open area on ‘land’ and ‘projection’ regions via ‘sandwich’ lightingtechnique DEFINE VARIABLES & OPEN FILES Open File ( C:\Data\39291\% OpenArea\data.xls, channel #1 ) MFLDIMAGE = 2 TOTCOUNT = 0 TOTFIELDS = 0SAMPLE ID AND SET UP Configure ( Image Store 1392 × 1040, Grey Images81, Binaries 24 ) Enter Results Header File Results Header ( channel #1) File Line ( channel #1 ) Image Setup DC Twain [PAUSE] ( Camera 1,AutoExposure Off, Gain 0.00,  ExposureTime 34.23 msec, Brightness 0,Lamp 38.83 ) Measure frame ( x 31, y 61, Width 1330, Height 978 ) Imageframe ( x 0, y 0, Width 1392, Height 1040 ) -- Calvalue = 0.0231 mm/pxCALVALUE = 0.0231 Calibrate ( CALVALUE CALUNITS$ per pixel ) ClearAccepts For ( SAMPLE = 1 to 1, step 1 ) Clear Accepts File ( “FieldNo.”, channel #1, field width: 9, left justified ) File ( “Land Area”,channel #1, field width: 9, left justified ) File ( “Land Open Area”,channel #1, field width: 13, left justified ) File ( “%Open Land Area”,channel #1, field width: 15, left justified ) File ( “Proj. Area”,channel #1, field width: 9, left justified ) File ( “Proj. Open Area”,channel #1, field width: 13, left justified ) File ( “% Open Proj.Area”, channel #1, field width: 15, left justified ) File ( “Total %Open Area”, channel #1, field width: 14, left justified ) File Line (channel #1 ) Stage ( Define Origin ) Stage ( Scan Pattern, 5 × 1 fields,size 82500.000000 × 82500.000000 ) IMAGE ACQUISITION I - Projectionisolation For ( FIELD = 1 to 5, step 1 )  Display ( Image0 (on), frames(on,on), planes (off,off,off,off,off,off), lut 0, x 0, y 0, z 1,Reduction off )  PauseText ( “Ensure incident lighting is correct (WL =0.88 - 0.94) and acquire  image.” )  Image Setup DC Twain [PAUSE] (Camera 1, AutoExposure Off, Gain 0.00,  ExposureTime 34.23 msec,Brightness 0, Lamp 38.83 )  Acquire ( into Image0 ) DETECT - Projectionsonly PauseText ( “Ensure that threshold is set at least to the right ofthe left gray-level  histogram peak which corresponds to the ‘land’region.” ) Detect [PAUSE] ( whiter than 127, from Image0 into Binary0delineated ) BINARY IMAGE PROCESSING Binary Amend (Close from Binary0 toBinary1, cycles 10, operator Disc, edge erode on) Binary Identify (FillHoles from Binary1 to Binary1 ) Binary Amend (Open from Binary1 toBinary2, cycles 20, operator Disc, edge erode on) Binary Amend (Closefrom Binary2 to Binary3, cycles 8, operator Disc, edge erode on )PauseText (“Toggle <control> and <b> keys to check bump detection andcorrect if necessary.” )  Binary Edit [PAUSE] ( Draw from Binary3 toBinary3, nib Fill, width 2 )  Binary Logical ( copy Binary3, inverted toBinary4 ) IMAGE ACQUISITION 2 - % Open Area Display ( Image0 (on),frames (on,on), planes (off,off,off,off,off,off), lut 0, x 0, y 0, z  1,Reduction off ) PauseText ( “Turn off incident light & ensuretransmitted lighting is correct (WL =  0.97) and acquire image.” ) Image Setup DC Twain [PAUSE] ( Camera 1, AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp 38.83 ) Acquire (intoImage0) DETECT - Open areas only Detect ( whiter than 210, from Image0into Binary10 delineated ) BINARY IMAGE PROCESSING Binary Logical ( C =A AND B : C Binary11, A Binary3, B Binary10 ) Binary Logical ( C = A ANDB : C Binary12, A Binary4, B Binary10 ) MEASURE AREAS - Land,projections, open area within each -- Land Area MFLDIMAGE = 4 Measurefield ( plane MFLDIMAGE, into FLDRESULTS(1), statistics intoFLDSTATS(7,1) ) Selected parameters: Area LANDAREA = FLDRESULTS(1) --Projection Area MFLDIMAGE = 3 Measure field ( plane MFLDIMAGE, intoFLDRESULTS(l), statistics into FLDSTATS(7,1) ) Selected parameters: AreaBUMPAREA = FLDRESULTS(1) -- Open Projection area MFLDIMAGE = 11 Measurefield ( plane MFLDIMAGE, into FLDRESULTS(l), statistics intoFLDSTATS(7,1)) Selected parameters: Area APBUMPAREA = FLDRESULTS(1) --Open land area MFLDIMAGE = 12 Measure field ( plane MFLDIMAGE, intoFLDRESULTS(l), statistics into  FLDSTATS(7,1)) Selected parameters: AreaAPLANDAREA = FLDRESULTS(1) -- Total % open area MFLDIMAGE = 10 Measurefield ( plane MFLDIMAGE, into FLDRESULTS(l), statistics intoFLDSTATS(7,1) ) Selected parameters: Area % TOTPERCAPAREA =FLDRESULTS(1) CALCULATE AND OUTPUT AREAS PERCAPLANDAREA =APLANDAREA/LANDAREA*100 PERCAPBUMPAREA = APBUMPAREA/BUMPAREA*100 File (FIELD, channel #1, 0 digits after ‘.’ ) File ( LANDAREA, channel #1,2digits after ‘.’ ) File (APLANDAREA, channel #1,2 digits after‘.’) File( PERCAPLANDAREA, channel #1, 1 digit after ‘.’ ) File ( BUMPAREA,channel #1, 2 digits after ‘.’ ) File ( APBUMPAREA, channel #1, 4 digitsafter ‘.’ ) File ( PERCAPBUMPAREA, channel #1, 5 digits after ‘.’ ) File( TOTPERCAPAREA, channel #1, 2 digits after ‘.’ ) File Line ( channel #1) Stage ( Step, Wait until stopped + 1100 msecs ) Next ( FIELD )PauseText ( “If no more samples, enter ‘0.’” ) Input ( FINISH ) If (FINISH=0 ) Goto OUTPUT Endif PauseText ( “Place the next replicatespecimen on the auto-stage, turn on incident light  and turn-off and/orblock sub-stage lighting.” ) Image Setup DC Twain [PAUSE] ( Camera 1,AutoExposure Off, Gain 0.00, ExposureTime 34.23 msec, Brightness 0, Lamp38.83 ) File Line (channel #1) Next ( SAMPLE ) OUTPUT: Close File (channel #1 ) END

The QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter the material set informationwhich is sent to the EXCEL file.

The analyst is next prompted by a live image set up window on thecomputer monitor screen to place a material onto the auto-stage 208. Thematerial should be laid flat and gentle force applied at its edges toremove any macro-wrinkles that may be present. It should also be alignedso that the machine direction runs horizontally in the image. At thistime, the Circline fluorescent lamp 214 can be on to assist inpositioning the material. Next, the analyst is prompted to adjust theincident Circline fluorescent lamp 214 via the Variable Auto-transformerto a white level reading of approximately 0.9. The sub-stage transmittedlight bank 218 should either be turned off at this time or masked usinga piece of light-blocking, black construction paper placed over the 3inch by 3 inch opening 224.

The analyst is now prompted to ensure that the detection threshold isset to the proper level for detection of the projections using theDetection window which is displayed on the computer monitor screen.Typically, the threshold is set using the white mode at a pointapproximately near the middle of the 8-bit gray-level range (e.g. 127).If necessary, the threshold level can be adjusted up or down so that theresulting detected binary will optimally encompass the projections shownin the acquired image with respect to their boundaries with thesurrounding land region.

After the algorithm automatically performs several binary imageprocessing steps on the detected binary of the projections, the analystwill be given an opportunity to re-check projection detection andcorrect any inaccuracies. The analyst can toggle both the ‘control’ and‘b’ keys simultaneously to re-check projection detection against theunderlying acquired gray-scale image. If necessary, the analyst canselect from a set of binary editing tools (e.g. draw, reject, etc.) tomake any minor adjustments. If care is taken to ensure properillumination and detection in the previously described steps, little orno correction at this point should be necessary.

Next, the analyst is prompted to turn off the incident Circlinefluorescent lamp 214 and either turn on the sub-stage transmitted lightbank or remove the light blocking mask. The sub-stage transmitted lightbank is adjusted by the Variable Auto-transformer to a white levelreading of approximately 0.97. At this point, the image focus can beoptimized for the land areas of the material.

The algorithm, after performing additional operations on the resultingseparate binary images for projections, land areas and open area, willthen automatically perform measurements and output the data into adesignated EXCEL spreadsheet file. The following measurement parameterdata will be located in the EXCEL file after measurements and datatransfer has occurred:

-   -   Land Area    -   Land Open Area    -   Land % Open Area    -   Projection Area    -   Projection Open Area    -   Projection % Open Area    -   Total % Open Area

Following the transfer of data, the algorithm will direct the auto-stage208 to move to the next field-of-view and the process of turning on theincident, Circline fluorescent lamp 214 and blocking the transmittedsub-stage lighting bank 218 will begin again. This process will repeatfour times so that there will be five sets of data from five separatefield-of-view images per single material replicate.

Multiple sampling replicates from a single material can be performedduring a single execution of the QUIPS algorithm (Note: The SampleFor—Next line in the algorithm needs to be adjusted to reflect thenumber of material replicate analyses to be performed per material). Thefinal material mean spread value is usually based on an N=5 analysisfrom five, separate, material subsample replicates. A comparison betweendifferent materials can be performed using a Student's T analysis at the90% confidence level.

Method for Determining Height of Projections

The height of the projections can be determined by using the imageanalysis measurement method described herein. The image analysis methoddetermines a dimensional numeric height value for projections usingspecific image analysis measurements of both land areas and projectionswith underlying land regions in a sample and then calculating theprojection height alone by difference between the two. The projectionheight method is performed using conventional optical image analysistechniques to detect cross-sectional regions of both land areas andprojection structures and then measure a mean linear height value foreach when viewed using a camera with incident lighting. The resultingmeasurement data are used to compare the projection heightcharacteristics of different types of body-side intake layers.

Prior to performing image analysis measurements, the sample of interestmust be prepared in such a way to allow visualization of arepresentative cross-section that passes thru the center of aprojection. Cross-sectioning can be performed by anchoring arepresentative piece of the sample on at least one of its cross-machinerunning straight edges on a flat, smooth surface with a strip of tapesuch as ¾ inch SCOTCH® Magic™ tape produced by 3M. Cross-sectioning isthen performed by using a new, previously unused single edge carbonsteel blue blade (PAL) and carefully cutting in a direction away fromand orthogonal to the anchored edge and thru the centers of at least oneprojection and preferably more if projections are arranged in rowsrunning in the machine direction. Any remaining rows of projectionslocated behind the cross-sectioned face of projections should be cutaway and removed prior to mounting so that only cross-sectionedprojections of interest are present. Such blades for cross-sectioningcan be acquired from Electron Microscopy Sciences of Hatfield, Pa. (Cat.#71974). Cross-sectioning is performed in the machine-direction of thesample, and a fresh, previously unused blade should be used for each newcross-sectional cut. The cross-sectioned face can now be mounted so thatthe projections are directed upward away from the base mount using anadherent such as two-side tape so that it can be viewed using a videocamera possessing an optical lens. The mount itself and any backgroundbehind the sample that will be viewed by the camera must be darkenedusing non-reflective black tape and black construction paper 317 (shownin FIG. 21), respectively. For a typical sample, enough cross-sectionsshould be cut and mounted separately from which a total of sixprojection height values can be determined.

An exemplary setup for acquiring the images is representativelyillustrated in FIG. 21. Specifically, a CCD video camera 300 (e.g., aLeica DFC 310 FX video camera operated in gray scale mode is availablefrom Leica Microsystems of Heerbrugg, Switzerland) is mounted on astandard support 302 such as a Polaroid MP-4 Land Camera standardsupport available from Polaroid Resource Center in Cambridge, Miss. orequivalent. The standard support 302 is attached to a macro-viewer 304such as a KREONITE macro-viewer available from Dunning Photo Equipment,Inc., having an office in Bixby, Okla. An auto stage 306 is placed onthe upper surface of the macro-viewer 304. The auto stage 306 is used tomove the position of a given sample for viewing by the camera 300. Asuitable auto stage 306 is a Model H112, available from Prior ScientificInc., having an office in Rockland, Mass.

The darkened sample mount 308 exposing the cross-sectioned sample facepossessing land areas and projections is placed on the auto stage 306under the optical axis of a 50 mm Nikon lens 310 with an f-stop settingof 2.8. The Nikon lens 310 is attached to the Leica DFC 310 FX camera300 using a 30 mm extension tube 312 and a c-mount adaptor. The samplemount 308 is oriented so the sample cross-section faces flush toward thecamera 300 and runs in the horizontal direction of the resulting imagewith the projections directed upward away from the base mount. Thecross-sectional face is illuminated with incident, incandescent lighting316 provided by two, 150 watt, GE Reflector Flood lamps. The two floodlamps are positioned so that they provide more illumination to thecross-sectional face than to the sample mount 308 beneath it in theimage. When viewed from overhead directly above the camera 300 andunderlying sample cross-section mount 308, the flood lamps 316 will bepositioned at approximately 30 degrees and 150 degrees with respect tothe horizontal plane running thru the camera 300. From this view thecamera support will be at the 90 degree position. The illumination levelof the lamps is controlled with a Variable Auto-transformer, type3PN1010, available from Staco Energy Products Co. having an office inDayton, Ohio.

The image analysis software platform used to perform measurements is aQWIN Pro (Version 3.5.1) available from Leica Microsystems, having anoffice in Heerbrugg, Switzerland.

The system and images are also calibrated using the QWIN software and astandard ruler with metric markings at least as small as one millimeter.The calibration is performed in the horizontal dimension of the videocamera image. Units of millimeters per pixel are used for thecalibration.

Thus, the method for determining projection heights of a given sampleincludes the step of performing several, dimensional measurements.Specifically, an image analysis algorithm is used to acquire and processimages as well as perform measurements using Quantimet User InteractiveProgramming System (QUIPS) language. The image analysis algorithm isreproduced below.

NAME = Height - Projection vs Land Regions - 1 PURPOSE = Measures heightof projection and land regions DEFINE VARIABLES & OPEN FILES -- Thefollowing line is set to designate where measurement data will bestored. Open File (C:\Data\39291\Height\data.xls, channel #1) FIELDS = 6SAMPLE ID AND SET UP Enter Results Header File Results Header ( channel#1 ) File Line ( channel #1 ) Measure frame (x 31, y 61, Width 1330,Height 978 ) Image frame ( x 0, y 0, Width 1392, Height 1040 ) --Calvalue = 0.0083 mm/pixel CALVALUE = 0.0083 Calibrate ( CALVALUECALUNITS$ per pixel ) For ( REPLICATE = 1 to FIELDS, step 1 ) ClearFeature Histogram #1 Clear Feature Histogram #2 Clear Accepts IMAGEACQUISITION AND DETECTION PauseText ( “Position sample, focus image andset white level to 0.95.” ) Image Setup DC Twain [PAUSE] ( Camera 1,AutoExposure Off, Gain 0.00, ExposureTime 200.00 msec, Brightness 0,Lamp 49.99 ) Acquire ( into Image0 ) ACQOUTPUT = 0 -- The following linecan be optionally set-up for saving image files to a specific location.ACQFILE$ = “C:\Images\39291 - for Height\Text.2H_“+STR$(REPLICATE)+”s.jpg” Write image ( from ACQOUTPUT into fileACQFILE$ ) Detect ( whiter than 104, from Image0 into Binary0 delineated) IMAGE PROCESSING Binary Amend (Close from Binary0 to Binary 1, cycles4, operator Disc, edge erode on) Binary Amend (Open from Binary1 toBinary2, cycles 4, operator Disc, edge erode on) Binary Identify(FillHoles from Binary2 to Binary3) Binary Amend (Close from Binary3 toBinary4, cycles 15, operator Disc, edge erode on) Binary Amend (Openfrom Binary4 to Binary5, cycles 20, operator Disc, edge erode on)PauseText ( “Fill in projection & land regions that should be included,and reject over detected regions.” ) Binary Edit [PAUSE] (Draw fromBinary5 to Binary6, nib Fill, width 2) PauseText ( “Select ‘Land’ regionfor measurement.” ) Binary Edit [PAUSE] ( Accept from Binary6 toBinary7, nib Fill, width 2 ) PauseText ( “Select ‘Projection’ region formeasurement.” ) Binary Edit [PAUSE] ( Accept from Binary6 to Binary8,nib Fill, width 2 ) -- Combine land and projection regions withmeasurement grid. Graphics ( Grid, 30 × 0 Lines, Grid Size 1334 × 964,Origin 21 × 21, Thickness 2, Orientation 0.000000, to Binary15 Cleared )Binary Logical ( C = A AND B : C Binary10, A Binary7, B Binary15 )Binary Logical ( C = A AND B : C Binary11, A Binary8, B Binary15 )MEASURE HEIGHTS -- Land region only Measure feature ( plane Binary10, 8ferets, minimum area: 8, grey image: Image0 ) Selected parameters: XFCP, Y FCP, Feret90 Feature Histogram #1 ( Y Param Number, X ParamFeret90, from 0.0100 to 5., logarithmic, 20 bins ) Display FeatureHistogram Results ( #1, horizontal, differential, bins + graph (Y axislinear), statistics ) Data Window ( 1278, 412, 323, 371 ) -- Projectionregions only (includes any underlying land material) Measure feature (plane Binary11, 8 ferets, minimum area: 8, grey image: Image0 ) Selectedparameters: X FCP, Y FCP, Feret90 Feature Histogram #2 ( Y Param Number,X Param Feret90, from 0.0100 to 10., logarithmic, 20 bins ) DisplayFeature Histogram Results ( #2, horizontal, differential, bins + graph(Y axis linear), statistics ) Data Window ( 1305, 801, 297, 371 ) OUTPUTDATA File ( “Land Height (mm)”, channel #1 ) File Line ( channel #1 )File Feature Histogram Results ( #1, differential, statistics, bindetails, channel #1 ) File Line ( channel #1 ) File Line ( channel #1 )File ( “Projection + Land Height (mm)”, channel #1 ) File Line ( channel#1 ) File Feature Histogram Results ( #2, differential, statistics, bindetails, channel #1 ) File Line ( channel #1 ) File Line ( channel #1 )File Line ( channel #1 ) Next (REPLICATE) Close File (channel #1) END

The QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter sample identificationinformation which is sent to a designated EXCEL file to which themeasurement data will also be subsequently sent.

The analyst is then prompted to position the mounted samplecross-section on the auto-stage 306 possessing the darkened backgroundso the cross-sectional face is flush to the camera 300 with projectionsdirected upward and the length running horizontally in the live imagedisplayed on the video monitor screen. The analyst next adjusts thevideo camera 300 and lens' 310 vertical position to optimize the focusof the cross-sectional face. The illumination level is also adjusted bythe analyst via the Variable Auto-transformer to a white level readingof approximately 0.95.

Once the analyst completes the above steps and executes the continuecommand, an image will be acquired, detected and processed automaticallyby the QUIPS algorithm. The analyst will then be prompted to fill-in thedetected binary image, using the computer mouse, of any projectionand/or land areas shown in the cross-sectional image that should havebeen included by the previous detection and image processing steps aswell as rejecting any over detected regions that go beyond theboundaries of the cross-sectional structure shown in the underlyinggray-scale image. To aid in this editing process, the analyst can togglethe ‘control’ and ‘B’ keys on the keyboard simultaneously to turn theoverlying binary image on and off to assess how closely the binarymatches with the boundaries of the sample shown in the cross-section. Ifthe initial cross-sectioning sample preparation was performed well,little if any manual editing should be required.

The analyst is now prompted to “Select ‘Land’ region for measurement”using the computer mouse. This selection is performed by carefullydrawing a vertical line down through one side of a single land arealocated between or adjacent to projections and then, with the left mousebutton still depressed, moving the cursor beneath the land area to itsopposite side and then drawing another vertical line upward. Once thishas occurred, the left mouse button can be released and the land area tobe measured should be filled in with a green coloring. If the verticaledges of the resulting selected region are skewed in any way, theanalyst can reset to the original detected binary by clicking on the‘Undo’ button located within the Binary Edit window and begin theselection process again until straight vertical edges on both sides ofthe selected land region are obtained.

Similarly, the analyst will next be prompted to “Select ‘Projection’region for measurement.” The top portion of a projection region adjacentto the previously selected land area is now selected in the same mannerthat was previously described for a land area selection.

The algorithm will then automatically perform measurements on bothselected regions and output the data, in histogram format, into thedesignated EXCEL spreadsheet file. In the EXCEL file, the histograms forland and projection regions will be labeled “Land Height (mm)” and“Projection+Land Height (mm),” respectively. A separate set ofhistograms will be generated for each selection of land and projectionregion pairs.

The analyst will then again be prompted to position the sample and beginthe process of selecting different land and projection regions. At thispoint, the analyst can either use the auto-stage joystick to move thesame cross-section to a new sub-sampling position or an entirelydifferent mounted cross-section obtained from the same sample can bepositioned on the auto-stage 306 for measurement. The process forpositioning the sample and selecting land and projection regions formeasurement will occur six times for each execution of the QUIPSalgorithm.

A single projection height value is then determined by calculating thenumerical difference between the mean values of the separate land andprojection region histograms for each single pair of measurements. TheQUIPS algorithm will provide six replicate measurement sets of both landand projection regions for a single sample so that six projection heightvalues will be generated per sample. The final sample mean spread valueis usually based on an N=6 analysis from six, separate subsamplemeasurements. A comparison between different samples can be performedusing a Student's T analysis at the 90% confidence level.

EXAMPLES Example 1

To demonstrate the process, apparatus and materials of the currentdisclosure, a series of fluid entangled body facing materials 28 weremade as well as projection layers 94 without support layers 92. Thesamples were made on a spunlace production line at Textor TechnologiesPTY LTD in Tullamarine, Australia, in a fashion similar to that shown inFIG. 15 of the drawings with the exception being that only oneprojection fluid entangling device 158 c was employed for forming theprojections 90 in the texturizing zone 178. In addition, the projectionlayer 94 was pre-wetted upstream of the process shown in FIG. 15 andprior to the pre-entangling fluid entangling device 158 a usingconventional equipment. In this case, the pre-wetting was achievedthrough the use of a single injector set at a pressure of 8 bar. Thepre-entangling fluid entangling device 158 a was set at 45 bar, thelamination fluid entangling device 158 b was set at 60 bar while thesingle projection fluid entangling device 158 c pressure was varied asset forth in Tables 1 and 2 below at pressures of 140, 160 and 180 bardepending on the particular sample being run.

For the transport belt 152 in FIG. 15, the pre-entangling fluid device158 a was set at a height of 10 mm above the transport belt 152. For thelamination forming surface 180 the lamination fluid entangling device158 b was set at a height of 12 mm above the surface 180 as was theprojection fluid entangling device 158 c with respect to the projectionforming surface 156.

The projection forming surface 156 was a 1.3 m wide steel texturizingdrum having a diameter of 520 mm, a drum thickness of 3 mm and ahexagonal close packed pattern of 4 mm round forming holes 170 separatedby 6 mm on a center-to-center spacing. The porous inner drum shell 174was a 100 mesh (100 wires per inch in both directions/39 wires percentimeter in both directions) woven stainless steel mesh wire. Theseparation or gap between the exterior of the shell 174 and the insideof the drum 156 was 1.5 mm.

The process parameters that were varied were the aforementionedentangling fluid pressures (140, 160 and 180 bar) and the degree ofoverfeed (0%, 11%, 25% and 43%) using the aforementioned overfeed ratioof OF=[(V₁/V₃)−1]×100 where V1 is the input speed of the projectionlayer 94 and V3 is the output speed of the resultant body facingmaterial 28.

All samples were run at an exit line or take-off speed (V3) ofapproximately 25 meters per minute (m/min). V1 is reported in the Tables1 and 2 for the samples therein. V2 was held constant for all samples inTables 1 and 2 at a speed equal to V3 or 25 meters per minute. Thefinished samples were sent through a line drier to remove excess wateras is usual in the hydroentanglement process. Samples were collectedafter the drier and then labeled with a code (see Tables 1 and 2) tocorrespond to the process conditions used.

Relative to the materials made, as indicated below in Tables 1 and 2,some were made with a support layer 92 and others were not and when asupport layer 92 was used, there were three variations including aspunbond web, a spunlace web and a through-air bonded carded web(TABCW). The spunbond support layer 92 was a 17 gsm polypropylene pointbonded web made from 1.8 denier polypropylene spunbond fibers which weresubsequently point bonded with an overall bond area per unit area of17.5% made by Kimberly-Clark Australia of Milsons Point, Australia. Thespunbond material was supplied and entered into the process in roll formwith a roll width of approximately 130 centimeters. The spunlace supportlayer 92 was a 52 gsm spunlace material using a uniform mixture of 70weight percent 1.5 denier, 40 mm long Viscose staple fibers and 30weight percent 1.4 denier, 38 mm long Polyester (PET) staple fibers madeby Textor Technologies PTY LTD of Tullamarine, Australia. The spunlacematerial was pre-formed and supplied in roll form and had a roll widthof approximately 140 centimeters. The TABCW support layer 92 had a basisweight of 40 gsm and comprised a uniform mixture of 40 weight percent, 6denier, 51 mm long PET staple fibers and 60 weight percent 3.8 denier,51 mm long polyethylene sheath/polypropylene core bicomponent staplefibers made by Textor Technologies PTY LTD of Tullamarine, Australia. Inthe data below (see Tables 1 and 2) under the heading “support layer”the spunbond layer was identified as “SB”, the spunlace layer wasidentified as “SL” and the TABCW layer was identified as “S”. Where nosupport layer 92 was used, the term “None” appears. The basis weightsused in the examples should not be considered a limitation on the basisweights that can be used as the basis weights for the support layers 92may be varied depending on the end applications.

In all cases the projection layer 94 was a carded staple fiber web madefrom 100% 1.2 denier, 38 mm long polyester staple fibers available fromthe Huvis Corporation of Daejeon, Korea. The projection layer 94 cardedweb was manufactured in-line with the hydroentanglement process byTextor Technologies PTY LTD of Tullamarine, Australia, and had a widthof approximately 140 centimeters. Basis weights varied as indicated inTables 1 and 2 and ranged between 28 gsm and 49.5 gsm though other basisweights and ranges may be used depending upon the end application. Theprojection layer 94 was identified as the “card web” in the data belowin Tables 1 and 2.

The thickness of the materials set forth in Tables 1 and 2 below as wellas in FIG. 22 were measured using a Mitutoyo model number ID-C1025Bthickness gauge with a foot pressure of 345 Pa (0.05 psi). Measurementswere taken at room temperature (about 20 degrees Celsius) and reportedin millimeters using a round foot with a diameter of 76.2 mm (3 inches).Thicknesses for select samples (average of three samples) with andwithout support layers are shown in FIG. 22 of the drawings.

The tensile strength of the materials, defined as the peak load achievedduring the test, was measured in both the Machine Direction (MD) and thecross-machine direction (CMD) using an Instron model 3343 tensiletesting device running an Instron Series IX software module Rev. 1.16with a +/−1 kN load cell. The initial jaw separation distance (“Gaugelength”) was set at 75 millimeters and the crosshead speed was set at300 millimeters per minute. Samples were cut to 50 mm width by 300 mmlength in the machine direction (MD) and each tensile strength testresult reported was the average of two samples per code. Samples wereevaluated at room temperature (about 20 degrees Celsius). Excessmaterial was allowed to drape out the ends and sides of the apparatus.Cross machine direction (CMD) strengths and extensions were alsomeasured and generally the CMD strengths were about one half to onefifth of MD strength and CMD extensions at peak load were about two tothree times higher than in the MD direction. (The CMD samples were cutwith the long dimension being taken in the CMD.) MD strengths werereported in Newtons per 50 mm width of material. (Results are shown inTables 1 and 2) MD extensions for the material at peak load werereported as the percentage of the initial gauge length (initial jawseparation).

Extension measurements were also made and reported in the MD at a loadof 10 Newtons (N). (See Tables 1 and 2 below and FIG. 23) Tables 1 and 2show data based upon varying the support layer being used, the degree ofoverfeed being used and variances in the water pressure from thehydroentangling water jets.

As an example of the consequences of varying process parameters, highoverfeed requires sufficient jet-pressure to drive the projection layer94 into the projection forming surface 156 and to take up the excessmaterial being overfed into the texturizing zone 178. If sufficient jetenergy is not available to overcome the material's resistance totexturing then the material will fold and overlap itself and in theworst case may lap a roller prior to the texturing zone 178 requiringthe process to be stopped. While the experiments were conducted at aline speed V3 of 25 m/min, this should not be considered a limitation asto the line speed as the equipment with similar materials was run atline speeds ranging from 10 to 70 meters per minute and speeds outsidethis range may be used depending on the materials being run.

The following tables (Tables 1 and 2) summarize the materials, processparameters, and test results. For the samples shown in Table 1, sampleswere made with and without support layers 92. Codes 1.1 through 3.6 usedthe aforementioned spunbond support layer 92. Codes 4.1 through 5.7 hadno support layer 92. Jet pressures for each of the samples are listed inTables 1 and 2.

TABLE 1 Experimental Parameters and test results, support layer 92 andno support layer 92, codes 1 to 5. Laminate* Card web Laminate*Laminate* Extension at Laminate* Support Card web Speed (V₁) Laminate*Thickness MD Strength Peak Load MD Extension CODE Layer (gsm) Overfeed(m/min) Press. (bar) Weight (gsm) (mm) (N/50 mm) MD (%) @10N (%) 1.1 SB28 43% 35.8 180 51 2.22 75.6 85.0 5.0 1.2 SB 28 43% 35.8 160 52.2 2.3365.8 82.1 3.5 1.3 SB 28 43% 35.8 140 51.1 2.34 61.3 86.1 3.4 1.4 SB 2811% 27.8 140 46.3 1.47 95.5 53.0 4.9 1.5 SB 28 11% 27.8 160 45.5 1.5291.9 46.7 4.7 1.6 SB 28 11% 27.8 180 46.7 1.61 109.1 49.8 5.0 1.7 SB 2825% 31.3 180 50.5 2.02 94.4 63.7 3.7 1.8 SB 28 25% 31.3 160 50.7 1.9782.1 62.2 5.6 1.9 SB 28 25% 31.3 140 49.7 1.99 74.9 62.8 4.2 1.10 SB 28 0% 25.0 140 42.9 1.08 104.4 35.8 3.0 1.11 SB 28  0% 25.0 160 43.6 1.15102.8 35.2 3.7 1.12 SB 28  0% 25.0 180 44.1 1.17 97.5 35.7 5.0 2.1 SB 2011% 27.8 140 36.8 1.27 53.1 44.2 2.4 2.2 SB 20 11% 27.8 160 36.2 1.2752.5 62.1 2.9 2.3 SB 20 11% 27.8 180 37.4 1.31 57.8 44.3 2.7 2.4 SB 2025% 31.3 180 39 1.55 53.4 56.6 2.4 2.5 SB 20 25% 31.3 160 38 1.48 46.663.4 2.8 2.6 SB 20 25% 31.3 140 38.8 1.46 39.7 30.4 2.3 2.7 SB 20 43%35.8 140 40.9 1.78 32.3 53.0 2.6 2.8 SB 20 43% 35.8 160 41.4 1.82 35.777.2 2.7 2.9 SB 20 43% 35.8 180 41.7 1.83 47.5 87.5 3.4 3.1 SB 38 25%31.3 180 62.2 2.52 97.3 64.8 2.2 3.2 SB 38 25% 31.3 160 61 2.47 93.563.5 2.3 3.3 SB 38 25% 31.3 140 60 2.32 83.9 68.2 2.4 3.4 SB 38 43% 35.8140 66.2 2.81 63.0 92.8 2.4 3.5 SB 38 43% 35.8 160 65.4 2.81 78.6 86.52.3 3.6 SB 38 43% 35.8 180 67.4 2.88 86.0 82.0 2.4 4.1 None 31.5 43%35.8 140 32.5 1.57 46.6 77.0 31.5 4.2 None 31.5 43% 35.8 160 38.1 1.9353.4 79.8 32.9 4.3 None 31.5 43% 35.8 180 35.9 2.04 46.4 69.3 31.1 4.4None 36.0 25% 31.3 180 35.8 1.47 57.4 53.8 19.0 4.5 None 36.0 25% 31.3160 36.3 1.58 56.1 49.7 17.1 4.6 None 36.0 25% 31.3 140 35.9 2.03 60.654.0 18.4 4.7 None 40.5 11% 27.8 140 38.8 1.3 69.0 41.3 15.1 4.8 None40.5 11% 27.8 160 38.2 1.33 72.4 41.4 9.9 4.9 None 40.5 11% 27.8 18037.6 1.31 72.3 36.6 8.4 5.1 None 38.5 43% 35.8 140 43.2 2.16 51.7 72.128.7 5.2 None 38.5 43% 35.8 160 44.1 2.2 54.2 76.1 26.0 5.3 None 38.543% 35.8 180 43.2 2.3 50.4 74.2 24.1 5.4 None 46.0 25% 31.3 180 40.51.77 67.5 51.8 13.6 5.5 None 46.0 25% 31.3 160 46.5 2.02 60.0 58.2 16.55.6 None 46.0 25% 31.3 140 45.8 1.99 61.1 54.8 20.2 5.7 None 49.5 11%27.8 140 43.6 1.52 74.0 36.8 9.2 5.8 None 49.5 11% 27.8 160 45 1.54 75.635.9 8.4 5.9 None 49.5 11% 27.8 180 47 1.71 70.8 39.1 8.9 *Note forcodes 4.1 to 5.9 the ”Laminate“ was a single layer structure as nosupport layer 92 was present.

For Table 2, samples 6SL.1 through 6SL.6 were run on the same equipmentunder the same conditions as the samples in Table 1 with theaforementioned spunlace support layer 92 while samples 6S.1 through 6S.4were run with the aforementioned through-air bonded carded web supportlayer 92. The projection layers 94 (“card webs”) were made in the samefashion as those used in Table 1.

TABLE 2 Experimental parameters and test results code 6, alternativesupport layers 92. Laminate Card web Laminate Laminate Extension atLaminate Support Card web Speed (V₁) Texturizing Jet Laminate ThicknessMD Strength Peak Load MD Extension CODE Layer (gsm) Overfeed (m/min)Press. (bar) Weight (gsm) (mm) (N/50 mm) MD (%) @10N (%) 6SL.1 SL 28 25%31.3 180 82.6 2.19 107.5 23.6 1.9 6SL.2 SL 28 25% 31.3 160 80 2.11 103.623.6 1.9 6SL.3 SL 28 25% 31.3 140 81.1 2.07 101.5 20.2 1.8 6SL.4 SL 2843% 35.8 140 85.4 2.16 86.7 20.2 1.7 6SL.5 SL 28 43% 35.8 160 84.2 2.5393.4 20.8 1.6 6SL.6 SL 28 43% 35.8 180 83.7 2.55 103.3 22.4 1.4 6S.1 S28 25% 31.3 180 68.2 2.56 89 56 4.2 6S.2 S 28 25% 31.3 160 70 2.57 7056.7 2.2 6S.3 S 28 25% 31.3 140 72.5 2.71 67.7 62 2.8 6S.4 S 28 43% 35.8140 78 2.63 48.5 57.8 2.8

As can be seen in Tables 1 and 2, the key quality parameter of fabricthickness depends predominantly on the amount of overfeed of theprojection layer 94 into the texturizing zone 178. Relative to the datashown in Table 2 it can be seen that high overfeed ratios resulted inincreased thickness. In addition, at the same overfeed ratios, higherfluid pressures resulted in higher thickness values which in turnindicates an increased projection 90 height. Table 2 shows the testresults for samples made using alternative support layers 92. Code 6Sused a 40 gsm through-air bonded carded web and code 6SL used a 52 gsmspunlaced material. These materials performed well and had goodstability and appearance when compared to unsupported materials with nosupport layers 92.

FIG. 22 depicts the sample thickness in millimeters relative to thepercentage of projection layer 94 overfeed for a body facing material 28(represented by a diamond) versus two samples that did not have asupport layer 92 (represented by a square and a triangle). All reportedvalues were an average of three samples. As can be seen from the data inFIG. 22, as overfeed is increased, the thickness of the sample alsoincreased showing the importance and advantage of using overfeed.

FIG. 23 is a graph depicting the percentage of sample extension at a 10Newton load relative to the amount of projection layer 94 overfeed formaterials from Table 1. As can be seen from the graph in FIG. 23, whenno support layer 92 was present, there was a dramatic increase in themachine direction extensibility of the resultant sample as thepercentage of overfeed of material into the texturizing zone 178 wasincreased. In contrast, the sample with the spunbond support layer 92experienced virtually no increase in its extension percentage as theoverfeed ratio was increased. This in turn resulted in the projectionlayer 94 having projections 90 which are more stable during subsequentprocessing and which are better able to retain their shape and height.

As can be seen from the data and the graphs, higher overfeed and hencegreater projection height also decreased the MD tensile strength andincreased the MD extension at peak load. This was because the increasedtexturing provided more material (in the projections) that did notimmediately contribute to resisting the extension and generating theload and allowed greater extension before the peak load was reached.

A key benefit of the laminate of both a projection layer 94 and asupport layer 92 compared to a single layer projection layer 94 with nosupport layer 92 can be that the support layer 92 can reduce excessiveextension during subsequent processing and converting which can pull outthe fabric texture and reduce the height of the projections. Without thesupport layer 92 being integrated into the projection forming process,it was very difficult to form webs with projections that could continueto be processed without the forces and tensions of the process actingupon the webs and negatively impacting the integrity of the projections,especially when low basis weight webs were desired. Other means can beused to stabilize the material such as thermal or adhesive bonding orincreased entanglement but they tend to lead to a loss of fabricsoftness and an increased stiffness as well as increasing the cost. Thefluid entangled body facing material 28 can provide softness andstability simultaneously. The difference between supported andunsupported textured materials is illustrated clearly in the last columnof Table 1 which, for comparison, shows the extension of the samples ata load of 10N. The data is also displayed in FIG. 23. It can be seenthat the sample supported by the spunbond support layer 92 extends onlya few percent at an applied load of 10 Newtons (N) and the extension wasalmost independent of the overfeed. In contrast the unsupportedprojection layer 94 extended by up to 30% at a 10 Newton load and theextension at 10N was strongly dependent on the overfeed used to texturethe material. Low extensions at 10N can be achieved for unsupported websbut only by having low overfeed, which results in low projection height,i.e., little texturing of the web.

FIG. 24 shows an example of the load-extension curves obtained intensile testing of samples in the machine direction (MD), which is thedirection in which highest loads are most likely to be experienced inwinding up the material and in further processing and converting. Thesamples shown were all made using an overfeed of 43% and approximatelythe same areal density (45 gsm).

It can be seen that the sample containing the spunbond support layer 92had a much higher initial modulus, the start of the curve was steepcompared to that of the unsupported, single projection layer 94 byitself. This steeper initial part of the curve for the sample was alsorecoverable as the sample was elastic up to the point where the gradientstarts to decrease. The unsupported sample has very low modulus andpermanent deformation and loss of texture occurs at a lower load. FIG.24 shows the load-extension curves for both a supported and unsupportedfabric. Note the relative steepness of the initial part of the curve forthe supported fabric/body facing material. This means that theunsupported sample is relatively easily stretched and a high extensionis required to generate any tension in it compared to the supportedsample. Tension is often required for stability in later processing andconverting but the unsupported sample is more likely to suffer permanentdeformation and loss of texture as a result of the high extension neededto maintain tension.

FIGS. 25 and 26 show the set of curves for a wider range of conditions.It can be seen that the samples with a low level of texturing from lowoverfeed were stiffer and stronger (despite being slightly lighter) butthe absence of texture rendered them not useful in this context. Allsupported laminate samples had higher initial gradients compared to theunsupported samples.

The level of improvement in the overall quality of the body facingmaterial 28 as compared to a projection layer 94 with no support layer92 can be seen by comparing the photos of the materials shown in FIGS.27, 27A, 28 and 28A. FIGS. 27 and 27A are photos of the samplerepresented by Code 3-6 in Table 1. FIGS. 28 and 28A are photos of thesample represented by Code 5-3 in Table 1. These codes were selected asthey both had the highest amount of overfeed (43%), and jet pressure(180 bar) using comparable projection layer 94 basis weights (38 gsm and38.5 gsm respectively) and thus the highest potential for goodprojection formation. As can be seen by the comparison of the two codesand accompanying photos, the supported web/laminate formed a much morerobust and visually discernible projections and uniform material thanthe same projection layer without a support layer. It also had betterproperties as shown by the data in Table 1. As a result, the supportedlaminate is much more suitable for subsequent processing and use in suchproducts as personal care absorbent articles.

FIG. 29 is a photo at the interface of a projection layer 94 with andwithout a support layer 92. As can be seen in this photo, the supportedprojection layer 94 has a much higher level of integrity. This isespecially important when the material is to be used in such endapplications as personal care absorbent articles where it is necessary(often with the use of adhesives) to attach the projection layer 94 tosubjacent layers of the product. With the unsupported projection layer,adhesive bleed through is a much higher threat. Such bleed through canresult in fouling of the processing equipment and unwanted adhesion oflayers thereby causing excessive downtime with manufacturing equipment.In use, the unsupported projection layer 94 is more likely to allowabsorbed fluids taken in by the absorbent article (such as blood, urine,feces and menses) to flow back or “rewet” the top surface of thematerial thereby resulting in an inferior product.

Another advantage evident from visual observation of the samples (notshown) was the coverage and the degree of flatness of the back of thefirst surface 96 on the external side of the support layer 92 and thusthe body facing material 28 resulting from the formation process whencompared to the inner surface 102 of a projection layer 94 run throughthe same apparatus 150 without a support layer 92. Without the supportlayer 92, the external surface of the projection layer 94 opposite theprojections 90 was uneven and relatively non-planar. In contrast, thesame external surface of the body facing material 28 with the supportlayer 92 was smoother and much flatter. Providing such flat surfacesimproves the ability to adhere the body facing material 28 to othermaterials in later converting. As noted in the exemplary productembodiments described herein, when body facing materials 28 according tothe present disclosure are used in items such as personal care absorbentarticles, having flat surfaces which readily interface with adjoininglayers is important in the context of joining the body facing material28 to other surfaces so as to allow rapid passage of body exudatesthrough the various layers of the absorbent article. If goodsurface-to-surface contact between layers is not present, fluid transferbetween the adjoining layers can be compromised.

Examples 2-11

In Examples 2-11 described herein, the following Table of MaterialDescriptions applies:

TABLE 3 Material Descriptions Material Code Material Description A BodyFacing Material: A dual layer fluid entangled body facing materialhaving 1) a support layer of 17 gsm polypropylene point bonded web madefrom 1.8 denier polypropylene spunbond fibers which were subsequentlypoint bonded with an overall bond area per unit area of 17.5% made byKimberly-Clark Australia of Milsons Point, Australia and 2) a projectionlayer of 38 gsm carded staple fiber web made from 100% 1.2 denier, 38 mmlong polyester staple fibers available from the Huvis Corporation ofDaejeon, Korea. The projection layer has about 4.4% open area in theland areas and has less than about 0.2% open area in the projections.The projection layer has a projection diameter of about 4 mm. The web ismade wettable with up to about 0.3% of 50:50 ratio of Ahcovel/SF-19 onthe bottom of the support layer and up to about 0.12% of Ahcovel on thetop of the projection layer. The web has a thickness of 2.4 mm whenmeasured under a pressure of 0.345 kPa. The web has a total basis weightof 55 gsm. The web is available from Textor Technologies PTY LTD ofTullamarine, Australia. B Body Facing Material: A dual layer fluidentangled body facing material having 1) a support layer of 10 gsmpolypropylene point bonded web made from 1.8 denier polypropylenespunbond fibers which were subsequently point bonded with an overallbond area per unit area of 17.5% made by Kimberly-Clark Australia ofMilsons Point, Australia and 2) a projection layer of 38 gsm cardedstaple fiber web made from 100% 1.2 denier, 38 mm long polyester staplefibers available from the Huvis Corporation of Daejeon, Korea. Theprojection layer has about 8.4% open area in the land areas and has lessthan about 0.1% open area in the projections. The projection layer has aprojection diameter of about 4 mm. The web is made wettable with up toabout 0.3% of 50:50 ratio of Ahcovel/SF-19 on the bottom of the supportlayer and up to about 0.12% of Ahcovel on the top of the projectionlayer. The web has a thickness of 2.4 mm when measured under a pressureof 0.345 kPa. The web has a total basis weight of 48 gsm. The web isavailable from Textor Technologies PTY LTD of Tullamarine, Australia. CBody Facing Material: A dual layer fluid entangled body facing materialhaving 1) a support layer of 10 gsm polypropylene point bonded web madefrom 1.8 denier polypropylene spunbond fibers which were subsequentlypoint bonded with an overall bond area per unit area of 17.5% made byKimberly-Clark Australia of Milsons Point, Australia and 2) a projectionlayer of 38 gsm carded staple fiber web made from 100% 1.2 denier, 38 mmlong polyester staple fibers available from the Huvis Corporation ofDaejeon, Korea. The projection layer has about 18.5% open area in theland areas and has less than about 0.5% open area in the projections.The projection layer has a projection diameter of about 4 mm. The web ismade wettable with up to about 0.3% of 50:50 ratio of Ahcovel/SF-19 onthe bottom of the support layer and up to about 0.12% of Ahcovel on thetop of the projection layer. The web has a thickness of 2.3 mm whenmeasured under a pressure of 0.345 kPa. The web has a total basis weightof 48 gsm. The web is available from Textor Technologies PTY LTD ofTullamarine, Australia. D Body Facing Material: A dual layer fluidentangled body facing material having 1) a support layer of 10 gsmpolypropylene point bonded web made from 1.8 denier polypropylenespunbond fibers which were subsequently point bonded with an overallbond area per unit area of 17.5% made by Kimberly-Clark Australia ofMilsons Point, Australia and 2) a projection layer of 38 gsm cardedstaple fiber web made from 100% 1.2 denier, 38 mm long polyester staplefibers available from the Huvis Corporation of Daejeon, Korea. Theprojection layer has greater than about 20% open area in the land areasand has less than about 1% interstitial fiber-to-fiber spacing in theprojections. The projection layer has a projection diameter of about 4mm. The web is made wettable with up to about 0.3% of 50:50 ratio ofAhcovel/SF-19 on the bottom of the support layer and up to about 0.12%of Ahcovel on the top of the projection layer. The web has a thicknessof 2.1 mm when measured under a pressure of 0.345 kPa. The web has atotal basis weight of 48 gsm. The web is available from TextorTechnologies PTY LTD of Tullamarine, Australia. E Secondary Liner: A13.5 gsm white wettable spunbond web composed of random laid continuouspolypropylene round filaments. The web is made wettable with up to about0.5% of a 52:18:30 ratio of Ahcovel/Glucopon/SF-19 using a foamingsystem. F Acquisition Layer: A 50 gsm through-air bonded-carded webcomposed of homogenous blend of 40% ES FiberVisions 7 denier T-118hollow polypropylene fibers and 60% ES FiberVisions 3 denier ESC-233bicomponent fibers. The web has a thickness of 1.15 mm when measuredunder a pressure of 0.345 kPa. The fibers are available from ESFiberVisions Corp., Duluth, GA, U.S.A G Acquisition Layer: A 50 gsmthrough-air bonded-carded web composed of homogenous blend of 40% ESFiberVisions 7 denier T-118 hollow polypropylene fibers and 60% ESFiberVisions 17 denier Varde bicomponent fibers. The web has a thicknessof 1.09 mm when measured under a pressure of 0.345 kPa. The fibers areavailable from ES FiberVisions Corp., Duluth, GA, U.S.A H AcquisitionLayer: A 50 gsm through-air bonded-carded web composed of homogenousblend of 50% ES FiberVisions 3 denier ESC-233 bicomponent fibers and 50%ES FiberVisions 1.5 denier ESC-215 bicomponent fibers. The web has athickness of 2.27 mm when measured under a pressure of 0.345 kPa. Thefibers are available from ES FiberVisions Corp., Duluth, GA, U.S.A IAcquisition Layer: A 50 gsm through-air bonded-carded web composed ofhomogenous blend of 50% Kelheim 3 denier Rayon Galaxy fibers and 50% ESFiberVisions 1.5 denier ESC-215 bicomponent fibers. The web has athickness of 0.57 mm when measured under a pressure of 0.345 kPa. TheKelheim fibers are available from Kelheim Fibers GmbH, RegensburgerStraBe 109, 93309 Kelheim, Germany. The ES FiberVisions fibers areavailable from ES FiberVisions Corp., Duluth, GA, U.S.A J Fluid TransferLayer: A white 16.6 gsm 100% elemental chlorine free, single ply, lowporosity creped wadding, water-cut-on-machine. This material isavailable from Cellu Tissue - Natural Dam, Gouverneur, N.Y., U.S.A. KFluid Transfer Layer: A 10 gsm white wettablespunbond-meltblown-spunbond web with the spunbond layers composed of 10gsm random laid continuous polypropylene round filaments and themeltblown layer composed of 10.4% meltblown fibers. The web is madewettable with up to 0.5% of a 52:18:30 ratio of Ahcovel/Glucopon/SF-19using a foaming system. L Fluid Transfer Layer: A 45 gsm layeredspunlace material composed of an 15 gsm spunbond polypropylene layer anda homogeneous 30 gsm hydraulically entangled (on the spunbond material)layer composed of about 48% Radiata Pine pulp supplied by J. Carter HoltHarvey Pulp and Paper and about 52% 6d polyester fibers supplied byHuvis. This material has a thickness of 0.32 mm when measured under apressure of 0.345 kPa. M Fluid Transfer Layer: Commercially availableScott Towels Select-A-Size from Kimberly-Clark Corporation, Neenah, WI.N Absorbent Body: A slightly hourglass shaped, flat absorbent pad airformed on commercially available equipment (such as from Curt Joa.,Sheboygan Falls, WI 53085) of a pulp fluff/superabsorbent materialhomogenous mixture with uniform thickness, density, and basis weight ona 12 gsm white spunbond-meltblown- spunbond backing sheet with a padlength of 287 mm and a pad width of 102 mm. The absorbent body contained50% superabsorbent material (SanDia SANWET KC990L, available fromSan-Dia Polymers, Ltd, Tokyo, Japan) and 50% pulp fluff (Weyerhaeuser7.5% moisture CF-416 Southern Softwood Kraft fluff pulp, available fromWeyerhaeuser Company, Geneva, Switzerland). O Absorbent Body: Arectangular, flat absorbent pad air formed on commercially availableequipment (such as from Curt Joa., Sheboygan Falls, WI 53085) of a pulpfluff/superabsorbent material homogenous mixture with uniform thickness,density, and basis weight on a 12 gsm white spunbond-meltblown-spunbondbacking sheet with a pad length of 287 mm and a pad width of 102 mm. Theabsorbent body contained 70% superabsorbent material (EVONIK SXM-9500,available from Evonik Stockhausen Inc., GmbH, Greensboro, NC, U.S.A.)and 30% pulp fluff (Weyerhaeuser 7.5% moisture CF-416 Southern SoftwoodKraft fluff pulp, available from Weyerhaeuser Company, Geneva,Switzerland). P Body Facing Material: A single layer fluid entangledbody facing material without any support layer and a total basis weightof 44 gsm constructed from a carded staple fiber made from 100% 1.2denier, 38 mm long polyester staple fibers available from the HuvisCorporation of Daejeon, Korea. The single layer material has projectionson a single side of the material with a projection diameter of about 4mm. The single layer material has about 17.8% open area in the landareas and has less than about 2.0% open area in the projections. The webhas a thickness of 2.2 mm when measured under a pressure of 0.345 kPa.The web is available from Textor Technologies PTY LTD of Tullamarine,Australia Q Commercially available Kotex Natural Balance Ultra ThinRegular With Wings feminine hygiene product manufactured byKimberly-Clark Corporation. R Commercially available Always ® Ultra ThinLong Super without wings products manufactured by the Procter & GambleCompany, Cincinnati, OH. S Acquisition Layer: 125 gsm airlaid with 16%PP/PE binder fibers and 84% Southern Softwood Kraft pulp. T AbsorbentBody: 200 gsm Airlaid with 16% PP/PE binder fiber and 84% SouthernSoftwood Kraft pulp and 15% superabsorbent material. U Body FacingMaterial: A dual layer fluid entangled body facing material having 1) asupport layer of 10 gsm polypropylene point bonded web made from 1.8denier polypropylene spunbond fibers which were subsequently pointbonded with an overall bond area per unit area of 17.5% made byKimberly-Clark Australia of Milsons Point, Australia and 2) a projectionlayer of 38 gsm carded staple fiber web made from 100% 1.2 denier, 38 mmlong polyester staple fibers available from the Huvis Corporation ofDaejeon, Korea. The projection layer has about 16.5% open area in theland areas and has less than about 0.25% open area in the projections.The projection layer has a projection diameter of about 4 mm. The web ismade wettable with up to about 0.3% of 50:50 ratio of Ahcovel/SF-19 onthe bottom of the support layer and up to about 0.12% of Ahcovel on thetop of the projection layer. The web has a thickness of 2.5 mm whenmeasured under a pressure of 0.345 kPa. The web has a total basis weightof 48 gsm. The web is available from Textor Technologies PTY LTD ofTullamarine, Australia.Fecal Material Simulant:

The following is a description of the fecal material simulant utilizedin some of the examples described herein.

Fecal Material Simulant Ingredients:

-   -   Dannon® All Natural Lowfat Yogurt (1.5% milkfat grade A),        Vanilla with other natural flavor, in 32 oz container.    -   McCormick Ground Turmeric    -   Great Value® 100% liquid egg whites    -   Knox® Original Gelatin—unflavored and in powder form    -   DAWN® Ultra Concentrated original scent dishwashing liquid    -   Distilled Water

Note: All fecal material simulant ingredients can be purchased atgrocery stores such as Wal-Mart® or on-line retailers. Some of the fecalmaterial simulant ingredients are perishable food items and should beincorporated into the fecal material simulant at least two weeks priorto their expiration date.

Fecal Material Simulant Mixing Equipment:

-   -   Laboratory Scale with an accuracy to 0.01 gram    -   500 mL beaker    -   Small lab spatula    -   Stop watch    -   IKA®-WERKE Eurostar Power Control-Visc with R 1312 Turbine        stirrer available from IKA® Works, Inc., Wilmington, N.C., USA.        Fecal Material Simulant Mixing Procedure:    -   1. A 4-part mixture is created at room temperature by adding, in        the following order, the following fecal material simulant        ingredients (which are at room temperature) to the beaker at a        temperature between 21° C. and 25° C.: 57% yogurt, 3% turmeric,        39.6% egg white and 0.4% gelatin. For example, for a total        mixture weight of 200.0 g, the mixture will have 114.0 g of the        yogurt, 6.0 g of the turmeric, 79.2 g of the egg whites, and 0.8        g of the gelatin using the laboratory scale.    -   2. The 4-part mixture should be stirred to homogeneity using the        IKA®-WERKE Eurostar stirrer set to a speed of 50 RPM.        Homogeneity will be reached in approximately 5 minutes (using        the stop watch). The beaker position can be adjusted during        stiffing so the entire mixture is stirred uniformly. If any of        the mixture material clings to the inside wall of the beaker,        the small spatula is used to scrap the mixture material off the        inside wall and place it into the center part of the beaker.    -   3. A 1.3% DAWN solution is made by adding 1.3 gram of DAWN Ultra        Concentrated into 98.7 gram of distilled water. The IKA®-WERKE        Eurostar and the R 1312 Turbine stirrer is used to mix the        solution for 5 minutes at a speed of 50 RPM.    -   4. An amount of 2.0 grams of the 1.3% DAWN solution is added to        200 grams of the 4-part mixture obtained from Step 2 for a total        combined weight of 202 grams of fecal material simulant. The 2.0        grams of the 1.3% DAWN solution is stirred into the homogenous        4-part mixture carefully and only to homogeneity (approximately        2 minutes) at a speed of 50 RPM, using the IKA®-WERKE Eurostar        stirrer. Final viscosity of the final fecal material simulant        should be 390±40 cP (centipoise) when measured at a shear rate        of 10 s⁻¹ and temperature of 37° C.    -   5. The fecal material simulant is allowed to equilibrate for        about 24 hours in a refrigerator at a temperature of 7° C. It        can be stored in a lidded and airtight container and        refrigerated for up to 5 days at around 7° C. Before use, the        fecal material simulant should be brought to equilibrium with        room temperature. It should be noted that multiple batches of        fecal material simulant of similar viscosity can be combined        together. For example, five batches of fecal material simulant        of similar viscosity and each 200 grams can be combined into one        common container for a total volume of 1000 cc. It will take        approximately 1 hour for 1000 cc of fecal material simulant to        equilibrate with room temperature.        Method to Determine the Viscosity of the Fecal Material        Simulant:

The viscosity of the fecal material simulant is determined utilizing aBrookfield rheometer. The final viscosity of the fecal material simulantshould be 390±40 cP (centipoise) when measured at a shear rate of 10 s⁻¹and a temperature of 37° C.

Equipment:

-   -   LV-model of the Brookfield DV-III ULTRA Rheometer with a spindle        #SCA-28    -   Rheocalc software provided by Brookfield        Method:    -   1. Gently invert (2 to 3 times by hand with slow rocking for        approximately 5 seconds) the sealed container of the fecal        material simulant prior to loading it into the cartridge to        reduce accumulation of particles on the bottom.    -   2. Per the instructions found in the Operator's Manual for the        Rheometer, the fecal material simulant is added, in an amount of        17 mL, to the cartridge via syringe and placed in the Thermosel        which is maintained at a constant temperature of 37° C.    -   3. Rheocalc is programmed to run at 30 second intervals between        each RPM (revolutions per minute) starting at 0.01 RPM followed        by 0.03, 0.07, 0.10, 0.50, 1.00, 3.00, 7.00, 10.0, 20.0, 50.0,        100.0, and 200.0 and going down to 100.0, 50.0, 20.0, 7.00,        3.00, 1.00, 0.50, 0.10, 0.07, 0.03, and 0.01.    -   4. The viscosity as a function of shear rate curve can be        established from the Rheocalc data. From that curve the        viscosity at a shear rate of 10/s can be determined.    -   5. The test is repeated three times using three different        batches of fecal material simulant to establish the range of        viscosity for the simulant at 10/s.        Experimental Absorbent Composites:

Experimental absorbent composites are utilized in some examplesdescribed herein. The following is a description of how the experimentalabsorbent composites are prepared.

Materials:

-   -   Outer Cover: Berry Plastics XP-8695H Inner Cover Film available        from Berry Plastics, Evansville, Ind., USA.    -   Body facing material, secondary liner, absorbent body,        acquisition layer, and fluid transfer layer are unique to each        example and specific materials are noted for each example as        described herein.    -   Construction Adhesive: H2525A available from Bostik Inc., U.S.A.    -   Construction Adhesive Glue Gun Nozzle: unibody spray nozzle with        a 0.012 inch orifice diameter as available as manufacturing part        No. 152168 from Nordson Corp., U.S.A.        Material Preparation:    -   1. Body facing material (if present in the composite): Cut to a        minimum size of 16 inches long by 6.5 inches wide.    -   2. Secondary Liner (if present in the composite): Cut to a        minimum size of 16 inches long by 6.5 inches wide.    -   3. Acquisition Layer (if present in the composite): Cut to a        size of 6 inches long by 4 inches wide.    -   4. Fluid Transfer Layer (if present in the composite): Cut to a        size of 11.3 inches long by 4 inches wide.    -   5. Outer Cover: Cut to a minimum size of 16 inches long by 6.5        inches wide.        Assembly Instructions for an Experimental Absorbent Composite        Having a Body Facing Material, Absorbent Body and Outer Cover:    -   1. Attach the absorbent body, centered in both the length and        the width directions, to the outer cover using 15 gsm of        construction adhesive to attach the backing sheet of the        absorbent body to the outer cover.    -   2. Apply 17.5 gsm of construction adhesive to the entire exposed        surface of the absorbent composite constructed so far, which        includes the exposed outer cover and absorbent body.    -   3. Attach the body facing material, centered in both the length        and width directions, to the absorbent composite, which includes        the outer cover and the absorbent body.    -   4. Smooth out any wrinkles in the body facing material and        ensure that it is tacked down to the adhesive.    -   5. Ensure that all the materials present in the composite are        adhered into place by pressing firmly on the perimeter 1.5        inches.    -   6. Cut out the assembled absorbent composite. Finished size        should be 6 inches wide by 15.5 inches long.    -   7. Mark the insult zone 6 inches from the back end of the        absorbent body with a single, small dot using a permanent        marker. The dot should be placed on the cross directional        midline of the absorbent body.        Assembly Instructions for an Experimental Absorbent Composite        Having a Body Facing Material, Fluid Transfer Layer, Absorbent        Body and Outer Cover:    -   1. Attach the absorbent body, centered in both the length and        the width directions, to the outer cover using 15 gsm of        construction adhesive to attach the backing sheet of the        absorbent body to the outer cover.    -   2. Attach the fluid transfer layer to the absorbent body using        11 gsm of construction adhesive. The midline of the width of the        fluid transfer layer should align with the midline of the width        of the absorbent body.    -   3. Apply 17.5 gsm of construction adhesive to the entire exposed        surface of the absorbent composite constructed so far, which        includes the exposed outer cover, absorbent body components, and        the fluid transfer layer.    -   4. Attach the body facing material, centered in both the length        and width directions, to the absorbent composite which includes        the outer cover, the absorbent body and the fluid transfer        layer.    -   5. Follow steps 4-7 listed above for an experimental absorbent        composite having a body facing material, absorbent body and        outer cover.        Assembly Instructions for an Experimental Absorbent Composite        Having a Body Facing Material, Acquisition Layer, Absorbent Body        and Outer Cover:    -   1. Attach the absorbent body, centered in both the length and        the width directions, to the outer cover using 15 gsm of        construction adhesive to attach the backing sheet of the        absorbent body to the outer cover.    -   2. Apply 17.5 gsm of construction adhesive to the entire exposed        surface of the absorbent composite constructed so far, which        includes the exposed outer cover and absorbent body.    -   3. Bond the acquisition layer to the body facing material using        the construction adhesive. The acquisition layer and body facing        material should be aligned on the midline of the width of the        body facing material.    -   4. Attach the body facing material and the acquisition layer to        the absorbent composite which includes the outer cover and the        absorbent body.    -   5. Follow steps 4-7 listed above for an experimental absorbent        composite having a body facing material, absorbent body and        outer cover.        Assembly Instructions for an Experimental Absorbent Composite        Having a Body Facing Material, Acquisition Layer, Fluid Transfer        Layer, Absorbent Body and Outer Cover:    -   1. Attach the absorbent body, centered in both the length and        the width directions, to the outer cover using 15 gsm of        construction adhesive to attach the backing sheet of the        absorbent body to the outer cover.    -   2. Attach the fluid transfer layer to the absorbent body using        11 gsm of construction adhesive. The midline of the width of the        fluid transfer layer should align with the midline of the width        of the absorbent body.    -   3. Apply 17.5 gsm of construction adhesive to the entire exposed        surface of the absorbent composite constructed so far, which        includes exposed outer cover, absorbent body components, and the        fluid transfer layer.    -   4. Bond the acquisition layer to the body facing material using        the construction adhesive. The acquisition layer and body facing        material should be aligned on the midline of the width of the        body facing material.    -   5. Attach the body facing material and the acquisition layer to        the absorbent composite which includes the outer cover, the        absorbent body and the fluid transfer layer. The acquisition        layer and fluid transfer layer should be aligned on the midline        of the width of the absorbent composite.    -   6. Follow steps 4-7 listed above for an experimental absorbent        composite having a body facing material, absorbent body and an        outer cover.        Assembly Instructions for an Experimental Absorbent Composite        Having a Body Facing Material, Secondary Liner, Acquisition        Layer, Fluid Transfer Layer, Absorbent Body and Outer Cover:    -   1. Attach the absorbent body, centered in both the length and        the width directions, to the outer cover using 15 gsm of        construction adhesive to attach the backing sheet of the        absorbent body to the outer cover.    -   2. Attach the fluid transfer layer to the absorbent body using        11 gsm of construction adhesive. The midline of the width of the        fluid transfer layer should align with the midline of the width        of the absorbent body.    -   3. Apply 17.5 gsm of construction adhesive to the entire exposed        surface of the absorbent composite constructed so far, which        includes exposed outer cover, absorbent body components, and the        fluid transfer layer.    -   4. Bond the secondary liner to the body facing material with the        construction adhesive. The secondary liner should be aligned on        the midline of the width of the body facing material.    -   5. Bond the acquisition layer to the secondary liner using the        construction adhesive. The acquisition layer, body facing        material, and secondary liner should be aligned on the midline        of the width of the body facing material.    -   6. Attach the body facing material, secondary liner and the        acquisition layer to the absorbent composite which includes the        outer cover, the absorbent body and the fluid transfer layer.        The acquisition layer and fluid transfer layer should be aligned        on the midline of the width of the absorbent composite.    -   7. Follow steps 4-7 listed above for an experimental absorbent        composite having a body facing material, absorbent body and an        outer cover.        Assembly Instructions for an Experimental Absorbent Composite        Having a Secondary Liner, Acquisition Layer, Fluid Transfer        Layer, Absorbent Body and Outer Cover:    -   1. Attach the absorbent body, centered in both the length and        the width directions, to the outer cover using 15 gsm of        construction adhesive to attach the backing sheet of the        absorbent body to the outer cover.    -   2. Attach the fluid transfer layer to the absorbent body using        11 gsm of construction adhesive. The midline of the width of the        fluid transfer layer should align with the midline of the width        of the absorbent body.    -   3. Apply 17.5 gsm of construction adhesive to the entire exposed        surface of the absorbent composite constructed so far, which        includes exposed outer cover, absorbent body components, and the        fluid transfer layer.    -   4. Bond the acquisition layer to the secondary liner using the        construction adhesive. The acquisition layer and the secondary        liner should be aligned on the midline of the width of the        secondary liner.    -   5. Attach the secondary liner and the acquisition layer to the        absorbent composite which includes the outer cover, the        absorbent body and the fluid transfer layer. The acquisition        layer and fluid transfer layer should be aligned on the midline        of the width of the absorbent composite.    -   6. Smooth out any wrinkles in the secondary liner and ensure        that it is tacked down to any adhesive not covered by the        acquisition layer.    -   7. Follow steps 5-7 listed above for an experimental absorbent        composite having a body facing material, absorbent body and an        outer cover.        Fecal Material Simulant Surface Spread and Fecal Material        Simulant Surface Residual:        Testing Equipment and Supplies:    -   Injection Apparatus (an exemplary set-up is illustrated in FIGS.        31 and 32)    -   Balance with an accuracy to 0.01    -   Electronic Digital Caliper (VWR International Model 62379-531)    -   Digital Thickness Gauge (Mitutoyo Type IDF-1050E, and exemplary        set-up is illustrated in FIG. 30)    -   Vacuum Box (an exemplary set-up is illustrated in FIGS. 34-36)    -   Digital Cooking Timer, readable to 1 second    -   Digital Camera (an exemplary set-up is illustrated in FIG. 33)    -   Ruler    -   Fecal Material Simulant, as described herein, utilized at room        temperature    -   Scott® paper towels (Mega Roll Choose A Size)    -   Absorbent composites for each absorbent composite test code as        described herein        Equipment Set-Up:    -   1. Pre-weigh a single paper towel which, as described below,        will be used to wipe the middle plate 244 of the injection        apparatus 240 clean of fecal material simulant.    -   2. Pre-weigh four sheets of paper towels which, as described        below, will be placed on top of the absorbent composite when the        absorbent composite is transitioned to the vacuum box.    -   3. With reference to FIG. 30, a Digital Thickness Gauge is        set-up to obtain the bulk measurement of an absorbent composite.        The Digital Thickness Gauge includes a granite base 232 having a        clamp shaft 231 where the top surface 233 of the granite base        232 is flat and smooth. A suitable granite base 232 is a Starret        Granite Base, model 653G (available from The L.S. Starrett        Company, having a place of business located in Athol, Mass.,        U.S.A.) or equivalent. A clamp arm 235 is secured to the clamp        shaft 231 at one end 236 of the clamp arm 235, and the digital        thickness gauge 230 is secured to the clamp arm 235 at the        opposing end 237. Extending downward from the digital thickness        gauge 230 is a vertically-movable plunger 238. Attached to the        distal end 239 of the plunger 238 is a circular platen 234        having a diameter of 76.2 mm. The platen 234 is constructed of        acrylic and is flat and smooth on at least the bottom surface.        The thickness and weight of the platen 234 is configured such        that the digital thickness gauge 230 provides a pressure of 0.05        psi (0.345 kPa). To zero the Digital Thickness Gauge 230, ensure        the granite surface 233 is clean of debris and position the        platen 234 and plunger 238 such that the bottom surface of the        platen 234 just touches the granite surface 233. After the        Digital Thickness Gauge 230 is zeroed, lift the platen 234 and        insert an absorbent composite between the platen 234 and the        granite surface 233. The absorbent composite must have a size        dimension of at least 90 mm by 102 mm. Lower the platen 234 and        plunger 238 such that the bottom surface of the platen 234 just        touches the surface of the absorbent composite as illustrated in        FIG. 30. A pressure of 0.05 psi (0.345 kPa) is applied to the        absorbent composite when the platen 234 is lowered. Measure and        record the bulk of 5 absorbent composites for each absorbent        composite test code. Calculate an average bulk for the absorbent        composite test code by averaging the bulk of the 5 absorbent        composites measured for each absorbent composite test code.    -   4. With reference to FIGS. 31 and 32, an injection apparatus 240        is set-up to deliver 10 cc of fecal material simulant at a rate        of 15 cc per sec. The injection apparatus 240 has a top plate        242, a middle plate 244, and a bottom plate 246. The top plate        242 has a height H1 of 12.42 mm, the middle plate 244 has a        height H2 of 12.2 mm, and the bottom plate has a height H3 of        12.2 mm. The top plate 242 and the bottom plate 246 each have a        length L1 of 305 mm and a width W1 of 165 mm. The top plate 242        is positioned over, aligned with, and connected to the bottom        plate 246 through the use of four threaded rods containing        plastic thumb knobs 248 located near the corners of each of the        top plate 242 and the bottom plate 246. Located between the top        plate 242 and the bottom plate 246, the middle plate 244 has a        length L2 of 152 mm and a width W2 of 102 mm and is suspended        from the center of the top plate 242 with the use of four bolts        250 located near the corners of the middle plate 244. The        injection apparatus 240 has a fecal material simulant injection        tube 252 located above and positioned perpendicular to the top        plate 242. The fecal material simulant injection tube 252 has a        length of 7 inches and an inside diameter of 6.4 mm. The tube is        made with Norprene® to allow for delivery of the fecal material        simulant through the tubing and onto the absorbent composite.        The fecal material simulant injection tube 252 connects to the        top plate 242, via a hose barbed fitting 243 having a diameter        of 0.25 inches. The hose barbed fitting 243 passes through the        top plate 242, via a hole cut into the top plate 242, and to the        middle plate 244, to deliver the fecal material simulant, via a        hole cut through the middle plate 244, to the absorbent        composite which is placed upon the surface of the bottom plate        246. The hose barbed fitting 243 is threaded into the middle        plate 244 to create a seal. The hole cut through the middle        plate 244 has an opening that is shaped like a cone 245 with a        0.88 inch diameter. The hose barbed fitting is manufactured by        Parker with a manufacturing number of 125HB-3-4 and is available        from MSC Industrial Supply Company. The fecal material simulant        injection tube 252 is held in place on the top plate 242 of the        injection apparatus 240 with a valve clamp block 254 containing        a solenoid pinch valve 255 which can open to allow the fecal        material simulant to pass through the tube 252 and close to        prevent the fecal material simulant from passing through the        tube 252. The solenoid pinch valve is a two-way, normally closed        valve with 24 VDC. The solenoid pinch valve is available from        NResearch, Inc., part number 648P012.    -   5. With reference to FIG. 33, a digital camera 260 operated in        color mode is set up to visually record the appearance of an        absorbent composite following delivery of fecal material        simulant. The digital camera 260 is a Pixelink (Model: PL-A742)        possessing a 1280×1024 pixel array and operating at a 10.2 Hertz        frame rate in color mode. A Pentax TV lens 262 (Model:        C6Z1218M3-2) is attached to the Pixelink camera 260 using a        c-mount adaptor. The Pentax lens 262 system allows the focus of        the lens 262 to be adjusted using accompanying software loaded        onto the system computer. The camera/lens 262 system is        connected to the computer via an ieee 1394 firewire (not shown).        The camera 260 and lens 262 are attached to a VP-400 Bencher        camera support 264. The Pentax lens face 268 is positioned at a        distance D4 of 94 cm above the base 266 of the VP-Bencher camera        support 264. An illuminated absorbent composite well 270 is        located at a distance D6 of 16 cm below the base 266 of the        VP-400 mount post 264. The distance D7 from the front face of        the Pantex lens 262 to the absorbent composite is 110 cm. The        absorbent composite well 270 is illuminated on all four sides        272 with a series of 18 Sylvania GE miniature fluorescent lights        with an output of 8 watts per bulb. A ⅛″ thick frosted glass        diffuser plate 271 is located between the bulbs and the        composite well 270. The camera 260 should be kept at the same        distance and settings for all images to eliminate variability        between absorbent composites. A ruler is placed in the absorbent        composite well 270 and is also captured in the digital image of        the absorbent composite for later spatial calibration reference        when determining the spread size of the fecal material simulant        on the absorbent composite. The images are acquired in JPEG        format.    -   6. With reference to FIGS. 34-36, a vacuum apparatus 320 is        prepared. The vacuum apparatus 320 comprises a vacuum chamber        322 supported on four leg members 324. The vacuum chamber 322        includes a front wall member 326, a rear wall member 328, and        two side wall members 330 and 332. The wall members are        sufficiently thick to withstand the anticipated vacuum pressures        (5 inches of water), and are constructed and arranged to provide        a chamber having outside dimensions measuring 23.5 inches        (59.7 cm) in length, 14 inches (35.6 cm) in width and 8 inches        (203 cm) in depth. A vacuum pump (not shown) operably connects        with the vacuum chamber 322 through an appropriate vacuum line        conduit and a vacuum valve 334. In addition, a suitable air        bleed line connects into the vacuum chamber 322 through an air        bleed valve 336. A hanger assembly 338 is suitably mounted on        the rear wall 328 and is configured with S-curved ends to        provide a convenient resting place for supporting a latex dam        sheet 340 in a convenient position away from the top of the        vacuum apparatus 320. A suitable hanger assembly 338 can be        constructed from 0.25 inch (0.64 cm) diameter stainless steel        rod. The latex dam sheet 340 is looped around a dowel member 342        to facilitate grasping and to allow a convenient movement and        positioning of the latex dam sheet 340. In the illustrated        position, the dowel member 342 is shown supported in a hanger        assembly 338 to position the latex dam sheet 340 in an open        position away from the top of the vacuum chamber 322. A bottom        edge of the latex dam sheet 340 is clamped against a rear edge        support member 344 with suitable securing means, such as toggle        clamps 346. The toggle clamps 346 mounted on the rear wall        member 328 with suitable spacers 348 which provide an        appropriate orientation and alignment of the toggle clamps 346        for the desired operation. Two support shafts 350 are 1.5 inches        in diameter and are removably mounted within the vacuum chamber        322 by means of support brackets 352. The support brackets 352        are generally equally spaced along the front wall member 326 and        the rear wall member 328 and arranged in cooperating pairs. In        addition, the support brackets 352 are constructed and arranged        to suitably position the uppermost portions of the support        shafts 350 flush with the top of the front, rear and side wall        members of the vacuum chamber 322. Thus, the support shafts 350        are positioned substantially parallel with one another and are        generally aligned with the side wall members 330 and 332. In        addition to the rear edge support member 344, the vacuum        apparatus 320 includes a front support member 354 and two side        support members 356 and 358. Each side support member measures        about 1 inch (2.5 cm) in width and about 1.25 inches (3.2 cm) in        height. The lengths of the support members are constructed to        suitably surround the periphery of the open top edges of the        vacuum chamber 322, and are positioned to protrude above the top        edges of the chamber wall members by a distance of about 0.5        inches. A layer of egg crating type material 360 is positioned        on top of the support shafts 350 and the top edges of the wall        members of the vacuum chamber 322. The egg crate material        extends over a generally rectangular area measuring 23.5 inches        (59.7 cm) by 14 inches (35.6 cm) and has a depth measurement of        about 0.38 inches (1.0 cm). The individual cells of the egg        crating structure measure about 0.5 inch square, and the thin        sheet material comprising the egg crating is composed of a        suitable material, such as polystyrene. For example, the egg        crating material can be McMaster-Carr Supply Catalog No. 1624K14        translucent diffuser panel material (available from        McMaster-Carr Supply Company, having a place of business in        Atlanta, Ga., U.S.A.). A layer of 6 mm (0.24 inch) mesh TEFLON        coated screening 362 (available from Eagle Supply and Plastics,        Inc., having a place of business in Appleton, Wis., U.S.A.)        which measures 23.5 inches (59.7 cm) by 14 inches (35.6 cm), is        placed on top of the egg crating material 360. A suitable drain        line and a drain valve 364 connect to the bottom plate member        366 of the vacuum chamber 322 to provide a convenient mechanism        for draining liquid from the vacuum chamber 322. The various        wall members and support members of the vacuum apparatus 320 may        be composed of a suitable non-corroding, moisture resistant        material, such as polycarbonate plastic. The various assembly        joints may be affixed by solvent welding and/or fasteners, and        the finished assembly of the vacuum apparatus 320 is constructed        to be water-tight. A vacuum gauge 368 operably connects through        a conduit 370 into the vacuum chamber 322. A suitable vacuum        gauge 368 is a Magnahelic differential gauge capable of        measuring a vacuum of 0-50 inches of water, such as a No. 2050C        gauge available from Dwyer Instrument Incorporated (having a        place of business in Michigan City, Ind., U.S.A.).        Delivery of Fecal Material Simulant and Determination of        Residual Fecal Material Simulant:    -   1. Adjust the positioning of the top plate 242 of the injection        apparatus 240 relative to the bottom plate 246 of the injection        apparatus 240 using the height adjustable screws 248 to raise        and lower the top plate 242 of the injection apparatus 240. The        top plate 242 of the injection apparatus 240 should be raised        and lowered for each absorbent composite test code based upon        the average bulk of each absorbent composite test code. As the        middle plate 244 is attached to the top plate 242, raising and        lowering the top plate 242 will also raise and lower the middle        plate 244. The top plate 242 of the injection apparatus 240        should be raised and lowered for each absorbent composite test        code so that the distance D8 between the bottom surface 256 of        the middle plate 244 and the top surface 258 of the bottom plate        246 is equivalent to the average bulk of the absorbent composite        test code being evaluated. After adjusting the position of the        top plate 242 to set the distance D8 a level should be placed on        top of the top plate 242 to ensure the top plate 242 is level.        If the top plate 242 is not level then the height adjustable        screws 248 should be adjusted to ensure the top plate 242 is        level while maintaining the distance D8.    -   2. Position an absorbent composite of an absorbent composite        test code between the middle plate 244 and the bottom plate 246        of the injection apparatus 240. Align the insult zone of the        absorbent composite underneath the fecal material simulant        injection tubing 252.    -   3. Zero the digital cooking thermometer.    -   4. Inject 10 cc of the fecal material simulant at a rate of 15        cc/sec through the fecal material simulant injection tube 252 to        deliver the fecal material simulant to the insult zone of the        absorbent composite.    -   5. Upon delivery of the fecal material simulant to the insult        zone of the absorbent composite, start the digital cooking timer        and allow the absorbent composite to remain undisturbed for two        minutes.    -   6. After the two minutes have elapsed, raise the top plate 242        and middle plate 244 of the injection apparatus 240, carefully        remove the absorbent composite from the injection apparatus 240,        keeping the absorbent composite flat and free from any        additional contact with the surfaces of the middle plate 244 and        top plate 242. The absorbent composite possessing a fecal        material simulant stain is placed into the illuminated absorbent        composite well 270, under the optical axis of the Pentax lens        262.    -   7. The absorbent composite is in a flat configuration and any        macro-sized wrinkles are removed by gentle manual manipulation        by the analyst. The absorbent composite is oriented so the        machine-direction (MD) runs in the horizontal direction of the        resulting image. The absorbent composite is illuminated with        fluorescent lighting. The lights are connected to a standard 110        volt energy source and are fully illuminated. Align the ruler        with the absorbent composite and photograph the absorbent        composite located in the absorbent composite well 270 using the        digital camera 260. The ruler is placed such that it is        displayed just beneath the absorbent composite in the image        (length-wise in the machine direction). The digital image of the        absorbent composite is used to determine, as described below,        the area of spread of the fecal material simulant.    -   8. The four sheets of pre-weighed paper towels are placed on the        egg crate material and the mesh TEFLON coated screen of the        vacuum apparatus. The four sheets are placed with the graphics        facing down towards the vacuum chamber. The four sheets are then        folded in half and then folded in half again. The absorbent        composite is then placed upside down on top of the four sheets        of paper towels. The latex dam sheet is then placed over the        absorbent composite and the four sheets of paper towels as well        as the entire egg crate material and TEFLON coated screen so        that the latex dam sheet created a seal when a vacuum is drawn        on the vacuum apparatus.    -   9. Apply vacuum pressure to the combination of the absorbent        composite and four sheets of pre-weighed paper towels at 5        inches of water (0.18 psi) for 1 minute.    -   10. After the 1 minute has elapsed, the latex dam sheet is        rolled back and the absorbent composite and four sheets of        pre-weighed paper towels are removed from the vacuum apparatus.        Remove the four sheets of pre-weighed paper towels from the        absorbent composite and re-weigh the four sheets of pre-weighed        paper towels. Determine the amount of simulated fecal material        transferred to the four sheets of pre-weighed paper towels by        subtracting the pre-weighed weight of the four sheets of paper        towels from the re-weighed weight of the four sheets of paper        towels.    -   11. Utilize the single pre-weighed paper towel to remove any        simulated fecal material simulant remaining on the middle plate        244 of the injection apparatus 240. Wipe the middle plate 244        with the pre-weighed paper towel to remove any remaining fecal        material simulant and re-weigh the single paper towel. Determine        the amount of fecal material simulant that remained on the        middle plate 244 by subtracting the pre-weighed weight of the        single paper towel from the re-weighed weight of the single        paper towel.    -   12. Determine the total amount of residual fecal material        simulant by adding together the amount of fecal material        transferred to the four sheets of pre-weighed paper towels and        the amount of fecal material simulant remaining on the middle        plate 244 of the injection apparatus 240.    -   13. Clean the injection apparatus middle plate 244 between each        injection of fecal material simulant.    -   14. Repeat the above procedure for each absorbent composite of        each absorbent composite test code.        Determination of Area of Spread of Fecal Material Simulant:

The area of spread of a fecal material simulant stain on a givencombination of absorbent article components can be determined by usingthe image analysis measurement method described herein. Generally, theimage analysis measurement method determines a dimensional numeric valueof area for a fecal material simulant stain via a combination ofspecific image analysis measurement parameters. The area of spread isdetermined using conventional optical image analysis techniques todetect stain regions and measure such parameters as the area when viewedusing a camera with incident lighting. An image analysis system,controlled by an algorithm, can detect and measure several otherdimensional properties of a fecal material simulant stain. The resultingmeasurement data can be used to compare the efficacy of differentcombinations of absorbent article layers with respect to restricting andminimizing the area of spread of a fecal material simulant.

The method for determining the area of spread of fecal material simulanton a given absorbent composite includes the step of acquiring a digitalimage of the absorbent composite following an insult with fecal materialsimulant, such as described above (see the method for the Delivery ofFecal Material Simulant). Following the acquisition of the digital imageof the absorbent composite, determining the area of spread of fecalmaterial simulant on a given absorbent composite includes the step ofperforming multiple, dimensional measurements. The image analysissoftware platform used to perform the dimensional measurements is a QWINPro (Version 3.5.1) available from Leica Microsystems, having an officein Heerbrugg, Switzerland. The system and images are also accuratelycalibrated using the QWIN software and a standard ruler with metricmarkings at least as small as one millimeter which is placed next to thesample during image acquisition. The calibration is performed in thehorizontal dimension of the video camera image. Units of centimeters perpixel are used for the calibration. Specifically, an image analysisalgorithm is used to process digital images as well as performmeasurements using Quantimet User Interactive Programming System (QUIPS)language. The image analysis algorithm is reproduced below.

NAME = Coverage-Size - BM on Diapers - 2a PURPOSE = Measures thecoverage and size of BM on body-side liner of absorbent product ENTERSAMPLE ID & OPEN DATA FILE PauseText ( “Enter EXCEL data file name now.”) Input ( FILENAME$ ) OPENFILE$ = “C:\Data\36775\“+FILENAME$+”.xls” OpenFile ( OPENFILE$, channel #CHAN ) CALIBRATE IMAGE - Calvalue = 0.0258cm/px CALVALUE = 0.0258 Calibrate ( CALVALUE CALUNITS$ per pixel ) EnterResults Header File Results Header ( channel #1 ) File Line ( channel #1) REPLICATE = 0 SAMPLE = 0 ACQOUTPUT = 0 SET-UP Image frame ( x 0, y 0,Width 1280, Height 1024 ) Measure frame ( x 31, y 61, Width 1218, Height962 ) For ( SAMPLE = 1 to 156, step 1 ) PauseText ( “Enter completeimage file title.” ) Input ( TITLE$ ) File ( TITLES, channel #1 ) FileLine ( channel #1 ) ACQUIRE IMAGE ACQOUTPUT = 0 -- Comment: Thefollowing line must be set to read from the directory where images arelocated. Read image [PAUSE] (from file C:\Images\36775 \areaSet\codeA3full1.jpg into Colour0) Colour Transform (RGB to HSI, fromColour0 to Colour0) Image Window (Auto Size, Auto Colour, No Auto Lut,Fit Image to Window, No Warning Before Image Overwrite, Do Not Load andSave Annotation with Image, Do Not Save Microscope Data with Image, DoNot Load and Save Reference Data with Image) DETECTION AND IMAGEPROCESSING PauseText (“Select optimal color detection”) Colour Detect[PAUSE] (HSI+: 134-183, 140-255, 88-255, from Colour0 into Binary0)Binary Identify (EdgeFeat from Binary0 to Binary0) Binary Amend (Closefrom Binary0 to Binary1, cycles 8, operator Disc, edge erode on) BinaryIdentify (FillHoles from Binary1 to Binary2) Binary Amend (Open fromBinary2 to Binary3, cycles 8, operator Disc, edge erode on ) PauseText (“Edit and select only those regions that should be measured.” ) BinaryEdit [PAUSE] (Accept from Binary3 to Binary4, nib Fill, width 2) MEASUREFEATURE PARAMETERS Measure feature ( plane Binary4, 32 ferets, minimumarea: 75, grey image: Colour0 ) Selected parameters: Area, X FCP, Y FCPFile Line ( channel #1 ) File Feature Results ( channel #1 ) File Line (channel #1 ) File Line ( channel #1 ) Next (SAMPLE) Close File ( channel#1 ) END

The QUIPS algorithm is executed using the QWIN Pro software platform.The analyst is initially prompted to enter in the EXCEL output data filename. This is followed by a prompting to enter the absorbent compositetest code information which is sent to the EXCEL file.

The analyst is now prompted to enter the complete digital image filetitle which can be obtained from the host computer directory listing ofthe digital images to be analyzed. The directory containing the imagesis typically placed on the host computer's hard drive and can beaccessed on the desktop screen via MS Windows. The image file titleinformation is now automatically sent to the EXCEL file. Next, the samedigital image file title can also be pasted into the Read Image windowprompt. This will now read the digital image from the directory into theQWIN software display. The digital image will show the absorbentcomposite and any fecal material simulant stain in color. Note that thecode line in the algorithm associated with reading the digital imagemust be pre-set to read from the designated host computer hard drivedirectory containing the files to be analyzed prior to algorithmexecution.

The analyst is now prompted to “Select optimal color detection” byadjusting the detection threshold, if necessary, in order to obtain theoptimal detection that is possible. The hue-saturation-intensity colordetection mode is used in the Coverage-Size—BM on Diapers—2a algorithm.Typically, only the saturation and/or the intensity levels will needslight adjustments to optimize detection. The detection settings for thealgorithm can be pre-determined before analyzing a set of images usingQWIN and the hue-saturation-intensity color detection mode within theQUIPS algorithm with a couple of representative images. Settings can beconsidered optimized when the stain is covered by the overlayingdetection binary with respect to its outer boundaries and areas withinsaid boundaries. The degree of match between the overlaying binary andstain images can be checked during optimization by toggling the binaryon and off using the ‘control’ and ‘B’ keys.

After detection and a series of automatic digital image processingsteps, the analyst is asked to “Edit and select only those regions thatshould be measured.” This is performed by simply using the computermouse to manually select the fecal material simulant stain region to bemeasured. The user can toggle the ‘control’ and ‘B’ keys on the keyboardsimultaneously to turn the overlying binary image on and off. A fitbetween the binary image and fecal material simulant stain is consideredgood when the binary image closely matches with the fecal materialsimulant stain with respect to its boundaries and regions within saidboundaries.

The algorithm will then automatically perform measurements and outputthe data into the designated EXCEL spreadsheet file. The followingprimary measurement parameter data will be located in the EXCEL fileafter measurements and data transfer has occurred:

Area

Multiple digital image replicates from a single or multiple absorbentcomposites can be performed during a single execution of the QUIPSalgorithm. The final sample mean spread value is usually based on an N=5analysis from five, separate, absorbent composites of an absorbentcomposite test code. A comparison between different samples can beperformed using a Student's T analysis at the 90% confidence level.

Example 2

The area of spread of fecal material simulant on an absorbent compositecan be measured. This measurement can provide an understanding of howwell a given absorbent composite design can minimize the surface spreadof fecal material across a body contacting surface of an absorbentcomposite. The area of spread, measured in cm², of the fecal materialsimulant can be determined after a 10 cc insult of fecal materialsimulant, as described herein, at 15 cc/sec.

In this example, eight different experimental absorbent composite testcodes were evaluated for the area of spread of fecal material simulanton the body contacting surface of the absorbent composite test code.Five absorbent composites for each absorbent composite test code wereassembled by hand according to Table 4 below, utilizing thecorresponding material descriptions listed in Table 3: MaterialDescriptions above. Each absorbent composite was subjected to thedelivery of a 10 cc insult of fecal material simulant, as describedherein, at 15 cc/sec and each absorbent composite of each absorbentcomposite test code was analyzed according to the Area of Spread ofFecal Material Simulant test method described herein.

TABLE 4 Experimental Absorbent Composite Test Codes: AcquisitionAbsorbent Body Second- Acqui- Layer Basis Fluid Absor- Composite Facingary sition Weight Transfer bent Test Code Material Liner Layer (gsm)Layer Body 1 A N/A G 50 K O 2 B N/A G 50 K O 3 C N/A G 50 K O 4 D N/A G50 K O 5 A N/A N/A N/A K O 6 B N/A N/A N/A K O 7 C N/A N/A N/A K O 8 DN/A N/A N/A K O

It should be noted that “N/A” means that for the absorbent compositetest code in question, that particular material is not present. Thus,for example, for Absorbent Composite Test Code 1, the absorbentcomposites assembled had Body Facing Material “A” (as described in Table3) adhesively bonded to Acquisition Layer “G” (as described in Table 3)without an additional layer of material between the two components. Itshould be understood that Body Facing Material “A” would be the bodycontacting surface of Absorbent Composite Test Code 1. Additionally, asan example, Absorbent Composite Test Code 5 is an absorbent compositeassembled with Body Facing Material “A” (as described in Table 3)adhesively bonded to Fluid Transfer Layer “K” (as described in Table 3)without any additional layers between the two components. It should beunderstood that Body Facing Material “A” would be the body contactingsurface of Absorbent Composite Test Code 5.

With regards to the absorbent composites assembled, the body facingmaterial is adhesively bonded to the body facing surface of theacquisition layer or the body facing surface of the fluid transferlayer, depending on the absorbent composite test code. If present, thegarment facing surface of the acquisition layer is adhesively bonded tothe fluid transfer layer. The fluid transfer layer is adhesively bondedto the absorbent body. The absorbent body is adhesively bonded to theouter cover (as described in Table 3). The absorbent composites did nothave any waist or leg elastics and did not have any containment flaps.

As illustrated in FIG. 37, the design of the absorbent composite has animpact on the amount of area of spread of fecal material simulant in anabsorbent composite test code. As illustrated in FIG. 37, the absorbentcomposite test codes that had an acquisition layer present as part oftheir design had lower area of spread of fecal material simulant thanthe absorbent composite test codes that did not have an acquisitionlayer present as part of their design. As illustrated in FIG. 37, withregards to the absorbent composite test codes containing an acquisitionlayer, the absorbent composite test codes having a body facing material28 with land areas having from about 5% to about 10% open area reducedthe area of spread of fecal material simulant to a greater extent thanthe remaining absorbent composite test codes which also contained anacquisition layer as part of their design.

Example 3

The area of spread of fecal material simulant on an absorbent compositecan be measured. This measurement can provide an understanding of howwell a given absorbent composite design can minimize the surface spreadof fecal material across a body contacting surface of an absorbentcomposite. The area of spread, measured in cm², of the fecal materialsimulant can be determined after a 10 cc insult of fecal materialsimulant, as described herein, at 15 cc/sec.

In this example, twenty different experimental absorbent composite testcodes were evaluated for the area of spread of fecal material simulanton the body contacting surface of the absorbent composite test code.Five absorbent composites for each absorbent composite test code wereassembled by hand according to Table 5 below, utilizing thecorresponding material descriptions listed in Table 3: MaterialDescriptions above. Each absorbent composite was subjected to thedelivery of a 10 cc insult of fecal material simulant, as describedherein, at 15 cc/sec and each absorbent composite of each absorbentcomposite test code was analyzed according to the Area of Spread ofFecal Material Simulant test method described herein.

TABLE 5 Experimental Absorbent Composite Test Codes AcquisitionAbsorbent Body Second- Acqui- Layer Basis Fluid Absor- Composite Facingary sition Weight Transfer bent Test Code Material Liner Layer (gsm)Layer Body 1 A N/A F 50 J N 2 A N/A F/F 100 J N 3 C N/A F 50 J N 4 C N/AF/F 100 J N 5 N/A E F 50 J N 6 A N/A G 50 J N 7 A N/A G/G 100 J N 8 CN/A G 50 J N 9 C N/A G/G 100 J N 10 N/A E G 50 J N 11 A N/A F 50 J O 12A N/A F/F 100 J O 13 C N/A F 50 J O 14 C N/A F/F 100 J O 15 N/A E F 50 JO 16 A N/A G 50 J O 17 A N/A G/G 100 J O 18 C N/A G 50 J O 19 C N/A G/G100 J O 20 N/A E G 50 J O

It should be noted that “N/A” means that for the absorbent compositetest code in question, that particular material is not present. Thus,for example, for Absorbent Composite Test Code 1, the absorbentcomposites assembled had Body Facing Material “A” (as described in Table3) adhesively bonded to Acquisition Layer “F” (as described in Table 3)without an additional layer of material between the two components. Itshould be understood that Body Facing Material “A” would be the bodycontacting surface of Absorbent Composite Test Code 1. Additionally, asan example, Absorbent Composite Test Code 5 is an absorbent compositeassembled with Liner “E” (as described in Table 3) adhesively bonded toAcquisition Layer “F” (as described in Table 3). It should be understoodthat Liner “E” would be the body contacting surface of AbsorbentComposite Test Code 5. It should also be noted that some absorbentcomposite test codes contained a double layer of acquisition layers asnoted in Table 5 above.

With regards to the absorbent composites assembled, the body facingmaterial or secondary liner, depending on the absorbent composite testcode, is adhesively bonded to the body facing surface of the acquisitionlayer. The garment facing surface of the acquisition layer is adhesivelybonded to the fluid transfer layer and the fluid transfer layer isadhesively bonded to the absorbent body. The absorbent body isadhesively bonded to the outer cover (as described in Table 3). Theabsorbent composites did not have any waist or leg elastics and did nothave any containment flaps.

As illustrated in FIG. 38, the design of the absorbent composite has animpact on the amount of area of spread of fecal material simulant in anabsorbent composite test code. As illustrated in FIG. 38, the absorbentcomposite test codes with the body facing material (Material Codes “A”and “C”) as the body contacting surface had lower area of spread offecal material simulant than the absorbent composite test codes that hadthe secondary liner material (Material Code “E”) as the body contactingsurface.

Example 4

The area of spread of fecal material simulant on an absorbent compositecan be measured. This measurement can provide an understanding of howwell a given absorbent composite design can minimize the surface spreadof fecal material across a body contacting surface of an absorbentcomposite. The area of spread, measured in cm², of the fecal materialsimulant can be determined after a 10 cc insult of fecal materialsimulant, as described herein, at 15 cc/sec.

In this example, six different experimental absorbent composite testcodes were evaluated for the area of spread of fecal material simulanton the body contacting surface of the absorbent composite test code.Five absorbent composites for each absorbent composite test code wereassembled by hand according to Table 6 below, utilizing thecorresponding material descriptions listed in Table 3: MaterialDescriptions above. Each absorbent composite was subjected to thedelivery of a 10 cc insult of fecal material simulant, as describedherein, at 15 cc/sec and each absorbent composite of each absorbentcomposite test code was analyzed according to the Area of Spread ofFecal Material Simulant test method described herein.

TABLE 6 Experimental Absorbent Composite Test Codes: AcquisitionAbsorbent Body Second- Acqui- Layer Basis Fluid Absor- Composite Facingary sition Weight Transfer bent Test Code Material Liner Layer (gsm)Layer Body 1 A N/A I 50 J N 2 C N/A I 50 J N 3 N/A E I 50 J N 4 A N/A H50 J N 5 C N/A H 50 J N 6 N/A E H 50 J N

It should be noted that “N/A” means that for the absorbent compositetest code in question, that particular material is not present. Thus,for example, for Absorbent Composite Test Code 1, the absorbentcomposites assembled had Body Facing Material “A” (as described in Table3) adhesively bonded to Acquisition Layer “I” (as described in Table 3)without any additional layer of material between the two components. Itshould be understood that Body Facing Material “A” would be the bodycontacting surface of Absorbent Composite Test Code 1. Additionally, asan example, Absorbent Composite Test Code 3 is an absorbent compositeassembled with Liner “E” (as described in Table 3) adhesively bonded toAcquisition Layer “I” (as described in Table 3). It should be understoodthat Liner “E” would be the body contacting surface of AbsorbentComposite Test Code 3.

With regards to the absorbent composites assembled, the body facingmaterial or secondary liner, depending on the absorbent composite testcode, is adhesively bonded to the body facing surface of the acquisitionlayer. The garment facing surface of the acquisition layer is adhesivelybonded to the fluid transfer layer and the fluid transfer layer isadhesively bonded to the absorbent body. The absorbent body isadhesively bonded to the outer cover (as described in Table 3). Theabsorbent composites did not have any waist or leg elastics and did nothave any containment flaps.

As illustrated in FIG. 39, the design of the absorbent composite has animpact on the amount of area of spread of fecal material simulant in anabsorbent composite test code. As illustrated in FIG. 39, the absorbentcomposite test codes with the body facing material (Material Codes “A”and “C”) as the body contacting surface had lower area of spread offecal material simulant than the absorbent composite test codes that hadthe secondary liner material (Material Code “E”) as the body contactingsurface.

Example 5

The amount of residual fecal material on the body contacting surface ofan absorbent composite can be measured. This measurement can provide anunderstanding of how well a given absorbent composite design canminimize the amount of residual fecal material pooling on the surface ofthe body contacting surface. The amount of residual fecal material canbe determined, as described herein, by measuring the weight, in grams,of the fecal material simulant that can be removed from the bodycontacting surface of the absorbent composite after two minutes.

In this example, eight different experimental absorbent composite testcodes were evaluated for the amount of residual fecal material simulanton the body contacting surface of the absorbent composite test code.Five absorbent composites for each absorbent composite test code wereassembled by hand according to Table 7 below, utilizing thecorresponding material descriptions listed in Table 3: MaterialDescriptions above. Each absorbent composite was subjected to thedelivery of a 10 cc insult of fecal material simulant, as describedherein, at 15 cc/sec and each absorbent composite of each absorbentcomposite test code was analyzed according to the Fecal MaterialSimulant Surface Residual test method described herein.

TABLE 7 Experimental Absorbent Composite Test Codes: AcquisitionAbsorbent Body Second- Acqui- Layer Basis Fluid Absor- Composite Facingary sition Weight Transfer bent Test Code Material Liner Layer (gsm)Layer Body 1 A N/A G 50 K O 2 B N/A G 50 K O 3 C N/A G 50 K O 4 D N/A G50 K O 5 A N/A N/A N/A K O 6 B N/A N/A N/A K O 7 C N/A N/A N/A K O 8 DN/A N/A N/A K O

It should be noted that “N/A” means that for the absorbent compositetest code in question, that particular material is not present. Thus,for example, for Absorbent Composite Test Code 1, the absorbentcomposites assembled had Body Facing Material “A” (as described in Table3) adhesively bonded to Acquisition Layer “G” (as described in Table 3)without any additional layers of material between the two components. Itshould be understood that Body Facing Material “A” would be the bodycontacting surface of Absorbent Composite Test Code 1. Additionally, asan example, Absorbent Composite Test Code 5 is an absorbent compositeassembled with Body Facing Material “A” (as described in Table 3)adhesively bonded to Fluid Transfer Layer “K” (as described in Table 3)without any additional layers between the two components. It should beunderstood that Body Facing Material “A” would be the body contactingsurface of Absorbent Composite Test Code 5.

With regards to the absorbent composites assembled, the body facingmaterial is adhesively bonded to the body facing surface of theacquisition layer or the body facing surface of the fluid transferlayer, depending on the absorbent composite test code. If present, thegarment facing surface of the acquisition layer is adhesively bonded tothe fluid transfer layer. The fluid transfer layer is adhesively bondedto the absorbent body. The absorbent body is adhesively bonded to theouter cover (as described in Table 3). The absorbent composites did nothave any waist or leg elastics and did not have any containment flaps.

As illustrated in FIG. 40, the design of the absorbent composite has animpact on the amount of residual fecal material simulant on the surfaceof an absorbent composite test code. As illustrated in FIG. 40, theabsorbent composite test codes that had an acquisition layer present aspart of their design had a larger amount of residual fecal materialsimulant on the surface of the body contacting surface of the absorbentcomposite than the absorbent composite test codes that did not have anacquisition layer present as part of their design.

Example 6

The amount of residual fecal material on the body contacting surface ofan absorbent composite can be measured. This measurement can provide anunderstanding of how well a given absorbent composite design canminimize the amount of residual fecal material pooling on the surface ofthe body contacting surface. The amount of residual fecal material canbe determined, as described herein, by measuring the weight, in grams,of the fecal material simulant that can be removed from the bodycontacting surface of the absorbent composite after two minutes.

In this example, twelve different experimental absorbent composite testcodes were evaluated for the residual amount of fecal material simulanton the body contacting surface of the absorbent composite test code.Five absorbent composites for each absorbent composite test code wereassembled by hand according to Table 8 below, utilizing thecorresponding material descriptions listed in Table 3: MaterialDescriptions above. Each absorbent composite was subjected to thedelivery of a 10 cc insult of fecal material simulant, as describedherein, at 15 cc/sec and each absorbent composite of each absorbentcomposite test code was analyzed according to the Fecal MaterialSimulant Surface Residual test method described herein.

TABLE 8 Experimental Absorbent Composite Test Codes: Absorbent BodyFluid Composite Facing Secondary Acquisition Transfer Absorbent TestCode Material Liner Layer Layer Body 1 B N/A N/A K O 2 C N/A N/A K O 3 DN/A N/A K O 4 B N/A N/A K N 5 C N/A N/A K N 6 D N/A N/A K N 7 B N/A N/AN/A O 8 C N/A N/A N/A O 9 D N/A N/A N/A O 10 B N/A N/A N/A N 11 C N/AN/A N/A N 12 D N/A N/A N/A N

It should be noted that “N/A” means that for the absorbent compositetest code in question, that particular material is not present. Thus,for example, for Absorbent Composite Test Code 1, the absorbentcomposites assembled had Body Facing Material “B” (as described in Table3) adhesively bonded to Fluid Transfer Layer “K” (as described in Table3) without any additional layers of material between the two components.It should be understood that Body Facing Material “B” would be the bodycontacting surface of Absorbent Composite Test Code 1. Additionally, asan example, Absorbent Composite Test Code 7 is an absorbent compositeassembled with Body Facing Material “B” (as described in Table 3)adhesively bonded to Absorbent Body “M” (as described in Table 3)without any additional layers between the two components. It should beunderstood that Body Facing Material “B” would be the body contactingsurface of Absorbent Composite Test Code 7.

With regards to the absorbent composites assembled, the body facingmaterial is adhesively bonded to the body facing surface of the fluidtransfer layer or the body facing surface of the absorbent body,depending on the absorbent composite test code. If present, the fluidtransfer layer is adhesively bonded to the absorbent body. The absorbentbody is adhesively bonded to the outer cover (as described in Table 3).The absorbent composites did not have any waist or leg elastics and didnot have any containment flaps.

As illustrated in FIG. 41, the design of the absorbent composite has animpact on the amount of residual fecal material simulant on the surfaceof an absorbent composite test code. As illustrated in FIG. 41, theabsorbent composite test codes that did not contain an acquisition layerand a fluid transfer layer as part of their design had a lower amount ofresidual fecal material simulant on the surface of the body contactingsurface of the absorbent composite than the absorbent composite testcodes that did not have an acquisition layer present but did have afluid transfer layer present as part of their design.

Example 7

The amount of residual fecal material on the body contacting surface ofan absorbent composite can be measured. This measurement can provide anunderstanding of how well a given absorbent composite design canminimize the amount of residual fecal material pooling on the surface ofthe body contacting surface. The amount of residual fecal material canbe determined, as described herein, by measuring the weight, in grams,of the fecal material simulant that can be removed from the bodycontacting surface of the absorbent composite after two minutes.

In this example, four different experimental absorbent composite testcodes were evaluated for the residual amount of fecal material simulanton the body contacting surface of the absorbent composite test code.Five absorbent composites for each absorbent composite test code wereassembled by hand according to Table 9 below, utilizing thecorresponding material descriptions listed in Table 3: MaterialDescriptions above. Each absorbent composite was subjected to thedelivery of a 10 cc insult of fecal material simulant, as describedherein, at 15 cc/sec and each absorbent composite of each absorbentcomposite test code was analyzed according to the Fecal MaterialSimulant Surface Residual test method described herein.

TABLE 9 Experimental Absorbent Composite Test Codes: Absorbent BodyFluid Composite Facing Secondary Acquisition Transfer Absorbent TestCode Material Liner Layer Layer Body 1 D N/A N/A J O 2 D N/A N/A L O 3 DN/A N/A M O 4 D N/A N/A K O

It should be noted that “N/A” means that for the absorbent compositetest code in question, that particular material is not present. Thus,for example, for Absorbent Composite Test Code 1, the absorbentcomposites assembled had Body Facing Material “D” (as described in Table3) adhesively bonded to Fluid Transfer Layer “J” (as described in Table3) without any additional layers of material between the two components.It should be understood that Body Facing Material “D” would be the bodycontacting surface of Absorbent Composite Test Code 1. Additionally, asan example, Absorbent Composite Test Code 3 is an absorbent compositeassembled with Body Facing Material “D” (as described in Table 3)adhesively bonded to Fluid Transfer Layer “M” (as described in Table 3)without any additional layers between the two components. It should beunderstood that Body Facing Material “D” would be the body contactingsurface of Absorbent Composite Test Code 3.

With regards to the absorbent composites assembled, the body facingmaterial is adhesively bonded to the body facing surface of the fluidtransfer layer. The fluid transfer layer is adhesively bonded to theabsorbent body. The absorbent body is adhesively bonded to the outercover (as described in Table 3). The absorbent composites did not haveany waist or leg elastics and did not have any containment flaps.

As illustrated in FIG. 42, the design of the absorbent composite has animpact on the amount of residual fecal material simulant on the surfaceof an absorbent composite test code. As illustrated in FIG. 42, theabsorbent composite test codes that had a fluid transfer layer composedof a tissue material or a hydroentangled material as part of theirdesign had a lower amount of residual fecal material simulant on thesurface of the body contacting surface of the absorbent composite thanthe absorbent composite test codes that had the Scott Towel or amaterial having polymeric materials as the fluid transfer layer as partof their design.

Example 8

The amount of residual fecal material on the body contacting surface ofan absorbent composite can be measured. This measurement can provide anunderstanding of how well a given absorbent composite design canminimize the amount of residual fecal material pooling on the surface ofthe body contacting surface. The amount of residual fecal material canbe determined, as described herein, by measuring the weight, in grams,of the fecal material simulant that can be removed from the bodycontacting surface of the absorbent composite after two minutes.

In this example, six different experimental absorbent composite testcodes were evaluated for the residual amount of fecal material simulanton the body contacting surface of the absorbent composite test code.Five absorbent composites for each absorbent composite test code wereassembled by hand according to Table 10 below, utilizing thecorresponding material descriptions listed in Table 3: MaterialDescriptions above. Each absorbent composite was subjected to thedelivery of a 10 cc insult of fecal material simulant, as describedherein, at 15 cc/sec and each absorbent composite of each absorbentcomposite test code was analyzed according to the Area of Spread ofFecal Material Simulant test method described herein.

TABLE 10 Experimental Absorbent Composite Test Codes: AcquisitionAbsorbent Body Second- Acqui- Layer Basis Fluid Absor- Composite Facingary sition Weight Transfer bent Test Code Material Liner Layer (gsm)Layer Body 1 A N/A I 50 J N 2 C N/A I 50 J N 3 N/A E I 50 J N 4 A N/A H50 J N 5 C N/A H 50 J N 6 N/A E H 50 J N

It should be noted that “N/A” means that for the absorbent compositetest code in question, that particular material is not present. Thus,for example, for Absorbent Composite Test Code 1, the absorbentcomposites assembled had Body Facing Material “A” (as described in Table3) adhesively bonded to Acquisition Layer “I” (as described in Table 3)without any additional layers of material between the two components. Itshould be understood that Body Facing Material “A” would be the bodycontacting surface of Absorbent Composite Test Code 1. Additionally, asan example, Absorbent Composite Test Code 3 is an absorbent compositeassembled with Liner “E” (as described in Table 3) adhesively bonded toAcquisition Layer “I” (as described in Table 3). It should be understoodthat Liner “E” would be the body contacting surface of AbsorbentComposite Test Code 3.

With regards to the absorbent composites assembled, the body facingmaterial or secondary liner, depending on the absorbent composite testcode, is adhesively bonded to the body facing surface of the acquisitionlayer. The garment facing surface of the acquisition layer is adhesivelybonded to the fluid transfer layer and the fluid transfer layer isadhesively bonded to the absorbent body. The absorbent body isadhesively bonded to the outer cover (as described in Table 3). Theabsorbent composites did not have any waist or leg elastics and did nothave any containment flaps.

As illustrated in FIG. 43, the design of the absorbent composite has animpact on the amount of residual fecal material simulant on the surfaceof an absorbent composite test code. As illustrated in FIG. 43, theabsorbent composite test codes with the body facing material (MaterialCodes “A” and “C”) as the body contacting surface had a lower amount ofresidual fecal material simulant on the surface of the absorbentcomposite test codes than the absorbent composite test codes that hadthe secondary liner material (Material Code “E”) as the body contactingsurface. From the information gathered in Example 2, it would have beenexpected that absorbent composite test codes 1, 2, 4 and 5 also wouldhave had a larger amount of residual fecal material simulant on thesurface of the body contacting surface of the absorbent composite testcodes. However, as illustrated in FIG. 43, absorbent composite testcodes 1, 2, 4 and 5, which each have an acquisition layer present intheir design, still had a lower amount of residual fecal materialsimulant on the surface of the body contacting surface of the absorbentcomposite test codes. As illustrated in FIGS. 40 and 43, if anacquisition layer is present in the design of the absorbent composite,the composition of the acquisition layer has an impact on the amount ofresidual fecal material simulant on the body contacting surface of theabsorbent composite. As illustrated in FIG. 43, an acquisition layerhaving smaller fiber denier can have a lower amount of residual fecalmaterial simulant on the body contacting surface of an absorbentcomposite than absorbent composites containing an acquisition layer withlarger fiber denier as part of its design.

Example 9

One-Cycle compression testing can be performed to measure thecompression resiliency of projections on single layer projection layersand dual layer body facing materials having a support layer and aprojection layer. Using measurements of the thickness of the unsupportedprojection layer and the dual layer body facing material during loadingand unloading, the percent resiliency can be determined.

In this example, an unsupported projection layer and two different bodyfacing materials were evaluated, following their removal from anabsorbent composite, for the percent resiliency of the unsupportedprojection layer and the dual layer body facing materials. Eachabsorbent composite was assembled by hand according to Table 11 below,utilizing the corresponding materials descriptions listed in Table 3:Material Descriptions above. Each unsupported projection layer and eachdual layer body facing material was analyzed according to the PercentResiliency—One Cycle Compression test method described herein.

TABLE 11 Experimental Absorbent Composite Test Codes: AbsorbentComposite Experimental Absorbent Test Code Liner Body 1 A O 2 C O 3 P O

With regards to the absorbent composites assembled, the experimentalliner is adhesively bonded to the body facing surface of the absorbentbody. The garment facing surface of the Absorbent body is adhesivelybonded to the outer cover. The absorbent composites do not have anywaist or leg elastics and does not have any containment flaps.

FIG. 44 illustrates the compressive stress versus liner thickness curvesunder the one-cycle loading and unloading for the unsupported projectionlayer and the two body facing materials tested.

Percent resiliency is calculated according to the following equation:% Resiliency=[(Thickness at 0.483 kPa unloading)/(Thickness at 0.483 kPaloading)]×100%

Table 12 provides a summary of the liner thicknesses at 0.483 kPa duringthe loading and unloading and the percent resiliency for the unsupportedprojection layer and the two body facing materials tested.

TABLE 12 Body Facing Material thickness (mm) under 0.483 kPa (0.07 psi)during loading and unloading and Percent Resiliency Liner P A C DuringLoading (mm) 1.56 1.44 1.91 During Unloading (mm) 1.08 1.19 1.47 %Resiliency 69 83 77

As indicated in Table 12, and as illustrated in FIG. 44, the percentresiliency of the single layer unsupported projection layer is around69%. As further indicated in Table 12, and as further illustrated inFIG. 44, the percent resiliency of a liner, such as a projection layerhaving projections, can be improved by combining a projection layer witha support layer to produce the body facing material.

Percent Resiliency—One Cycle Compression Test Method

-   -   1. Use “freeze off” spray to carefully remove the unsupported        projection layer or body facing material with projections from        an absorbent composite.    -   2. From the unsupported projection layer or body facing        material, cut a 38 mm by 25 mm test sample.    -   3. The upper and lower platens made of stainless steel are        attached to a tensile tester (Model: Alliance RT/1 manufactured        by MTS System Corporation, a business having a location in Eden        Prairie, Minn., U.S.A.)    -   4. The top platen has a diameter of 57 mm while the lower platen        has a diameter of 89 mm. The upper platen is connected to a 100        N load cell while the lower platen is attached to the base of        the tensile tester.    -   5. TestWorks Version 4 software program provided by MTS is used        to control the movement of the upper platen and record the load        and the distance between the two platens.    -   6. The upper platen is activated to slowly move downward and        touch the lower platen until the compression load reaches around        5000 g. At this point, the distance between the two platens is        zero.    -   7. The upper platen is then set to move upward (away from the        lower platen) until the distance between the two platens reaches        15 mm.    -   8. The crosshead reading shown on TestWorks Version 4 software        program is set to zero.    -   9. A test sample is placed on the center of the lower platen        with the projections facing toward the upper platen.    -   10. The upper platen is activated to descend toward the lower        platen and compress the test sample at a speed of 25 mm/min. The        distance that the upper platen travels is indicated by the        crosshead reading. This is a loading process.    -   11. When 345 gram force (about 3.5 kPa) is reached, the upper        platen stops moving downward and returns at a speed of 25 mm/min        to its initial position where the distance between the two        platens is 15 mm. This is an unloading process.    -   12. The compression load and the corresponding distance between        the two platens during the loading and unloading are recorded on        a computer using TestWorks Version 4 software program provided        by MTS.    -   13. The compression load is converted to the compression stress        by dividing the compression force by the area of the test        sample.    -   14. The distance between the two platens at a given compression        stress represents the thickness under that particular        compression stress.    -   15. A total of three test samples are tested for each test        sample code to get representative loading and unloading curves        for each test sample code.

Example 10

To measure the resistance to stretching and the associated collapse ofprojections, the percent extension under varying loads of an unsupportedprojection layer and a dual layer body facing material can be measured.

In this example, an unsupported projection layer and two different duallayer body facing materials were evaluated, following their removal froman absorbent composite, for the percent extension under varying loads ofthe unsupported projection layer and the body facing material. Eachabsorbent composite was assembled by hand according to Table 13 below,utilizing the corresponding material descriptions listed in Table 3:Material Descriptions above. Each unsupported projection layer and bodyfacing material was analyzed according to the Load vs. Percent Extensiontest method described herein.

TABLE 13 Experimental Absorbent Composite Test Codes: AbsorbentComposite Body Facing Absorbent Test Code Material Body 1 A O 2 C O 3 PO

With regards to the absorbent composites assembled, the unsupportedprojection layer or body facing material is adhesively bonded to thebody facing surface of the absorbent body. The garment facing surface ofthe absorbent body is adhesively bonded to the outer cover. Theabsorbent composites do not have any waist or leg elastics and does nothave any containment flaps.

FIG. 45 illustrates the load (N/25 mm) versus percent extension for theunsupported projection layer and the two body facing materials tested.

Table 14 provides a summary of the load versus percent extension for theunsupported projection layer and the two body facing materials tested.

TABLE 14 Load (N/25 mm) vs. % Extension at Various Loads Load %Extension (Newton/25 mm width) P A C 0 0 0 0 2.0 14 1.9 5.4 4.0 23 3.28.8 6.0 28 4.7 13

As illustrated in FIG. 45 and as summarized in Table 14, at a givenload, the percent elongation of a dual layer body facing material isless than that of a single layer unsupported projection layer. Thisdemonstrates the benefit of incorporating a support layer into a bodyfacing material to provide support to the projection layer of the bodyfacing material. The dual layer body facing material can have animproved resistance to stretching and maintenance of the height of theprojections of the body facing material.

Tensile Force Versus Percent Tensile Strain Test Method

-   -   1. Use “freeze off” spray to carefully remove the unsupported        projection layer or the body facing material with projections        from an absorbent composite.    -   2. Once the unsupported projection layer or body facing material        is removed from the absorbent composite, a 25 mm wide by 150 mm        long test sample is cut from the unsupported projection layer or        body facing material. The length direction of the test sample is        the machine direction of the unsupported projection layer or        body facing material and absorbent composite.    -   3. The test sample is clamped between two jaws of the Load vs        Percent Extension test equipment (Model: Alliance RT/1        manufactured by MTS System Corporation, a business having a        location in Eden Prairie, Minn., U.S.A.) The initial separation        between the two jaws is 125 mm.    -   4. The upper jaw is activated to travel away from the lower jaw        at a speed of 3.75 cm/min.    -   5. The upper jaw travels about 38 mm before it is stopped.    -   6. The percent extension versus load curve is recorded on a        computer using TestWorks Version 4 software program provided by        MTS.    -   7. A total of three samples are tested for each test sample to        obtain an average curve.

Example 11

The intake and rewet of feminine hygiene absorbent composites andcommercially available products utilizing simulated menses can beevaluated as described herein.

In this example, three different body facing materials and twocommercially available feminine hygiene products were evaluated fortheir intake and rewet capabilities. Each experimental feminine padabsorbent composite was assembled by hand according to Table 15 below,utilizing the corresponding material descriptions listed in Table 3:Material Descriptions above. Each body facing material and absorbentcomposite was analyzed according to the Intake/Rewet test methoddescribed herein utilizing menses simulant as described herein. Withregards to the absorbent composites assembled, the body facing materialis adhesively bonded to the body facing surface of the acquisitionlayer. The adhesive is applied, in a 1.5 to 2 inch width to the centerportion of the body facing material, to the support layer of the bodyfacing material (i.e., non-projection side of the body facing material).The garment facing surface of the acquisition layer is adhesively bondedto the absorbent body.

TABLE 15 Experimental Feminine Pad Absorbent Composite Test Codes: TestCode Body Facing Material Acquisition Layer Absorbent Body 1 B S T 2 C ST 3 U S T

Test Codes 4 and 5 are material codes, Q and R, respectively, asdescribed in Table 3: Material Descriptions above. Each of thecommercially available products was analyzed according to theIntake/Rewet test method described herein utilizing menses simulant asdescribed herein.

Table 16 provides a summary of the intake and rewet values for the threebody facing materials tested and the two commercially available productstested.

TABLE 16 Intake/Rewet Values: Test Code 1 2 3 4 5 Intake 1 Avg 7.59 7.087.68 11.09 8.56 Std 0.3 0.34 0.34 0.67 0.59 Intake 2 Avg 14.46 10.7911.22 31.4 21.07 Std 1.25 0.61 0.99 3.69 3.28 Rewet Avg 1.65 1.56 1.631.66 1.95 Std 0.07 0.08 0.06 0.05 0.06

As summarized in Table 16, the second intake time is less than andtherefore faster than the commercially available products. Thisindicates that the body facing material can capture the fluid faster andcan decrease the probability of leakage caused by slow fluid capture bythe commercially available products. Typically, intake times areimproved at the expense of rewet amount. In this case, while the secondintake time is faster with the body facing materials, no increase inrewet amount compared to the commercial products is found.

Menses Simulant Preparation:

The menstrual simulant was prepared using porcine blood and egg whitefrom chicken eggs per the following protocol as published in IP.com onAug. 6, 2010, reference number IPCOM000198395D. This procedure is abatch process that can produce 2.5 L to 4.0 L of fluid. Menses simulantcan be purchased from Cocalico Biologicals, Reamstown Pa.1. Apparatus:

-   -   1.1. Stirrer and stand    -   1.2. Stirring rod with 3″ diameter flat blade    -   1.3. 3 L reaction vessel    -   1.4. Plastic strainer    -   1.5. Preparatory centrifuge    -   1.6. Hematocrit centrifuge    -   1.7. Motorized pipettor        2. Materials and supplies:    -   2.1 Fresh jumbo chicken eggs    -   2.2 Defibrinated porcine blood    -   2.3 Defibrinated porcine plasma    -   2.4 Parafilm    -   2.5 Micro-hematocrit capillary tubes    -   2.6 Critoseal sealant (Oxford Labware)        3. Protocol    -   3.1. Collection, separation and processing of thick egg white        -   3.1.1. Using fresh, jumbo chicken eggs, one at a time,            remove the egg from its shell and place in a yolk-separator            set on the rim of a 250 mL beaker. Allow the egg white to            pass through the yolk-separator and into the 250 mL beaker,            and then discard the yolk. Remove any chalazae from the egg            white using a rounded soup spoon and transfer the egg white            to a 600 mL beaker. This process is continued until 12 eggs            have been processed and collected in the 600 mL beaker.        -   3.1.2. Transfer the egg whites from 12 eggs into the plastic            filter/collection bowl and allow the thin egg white to drain            through the filter into the collection bowl for 10 minutes.            Tip the filter bowl from side to side every 3-4 minutes            during this process to facilitate drainage of the thin egg            white. Discard the thin egg white.        -   3.1.3. Place a clean collection bowl under the filter bowl            containing the retained thick egg white and, using the back            of a soup spoon, press the thick egg white through the            openings in the filter bowl and into the collection bowl.        -   3.1.4. Place the processed thick egg white in a 1.5 or 2 L            beaker        -   3.1.5. Repeat the processing of 12 eggs until sufficient            thick egg white has been collected.    -   3.2. Preparation of porcine blood plasma        -   3.2.1. Pour porcine blood into 750 mL plastic centrifuge            buckets (maximum 500 mL in each bucket) and place buckets in            carriers. Centrifuge buckets must be filled in pairs.        -   3.2.2. Carefully balance pairs of buckets, in their            carriers, on a beam balance by transferring blood from one            bucket to the other. Then place buckets and carriers in the            centrifuge.        -   3.2.3. Centrifuge the balanced buckets at 3500 rpm for 60            minutes at room temperature.        -   3.2.4. Carefully remove plasma from each bucket using a 10            mL pipette and a pipette motor and place in a 1 L beaker.            Keep tip of pipette at least 5 mm above the packed red blood            cell layer to avoid aspirating the red cells and            contaminating the plasma.        -   3.2.5. Alternatively, defibrinated porcine plasma may be            purchased from Cocalico Biologicals, Inc.            -   3.2.5.1. If purchased plasma is used, place the plasma                in 750 mL centrifuge buckets and balance the buckets, as                described above.            -   3.2.5.2. Centrifuge the plasma at 3500 rpm for 30                minutes at room temperature. This procedure will                separate the plasma from any precipitate that may be                present.            -   3.2.5.3. Decant the clarified plasma by carefully                pouring the fluid into a 1 L beaker.    -   Preparation of packed porcine red blood cells        -   3.2.6. Follow the procedure above for preparation of porcine            blood plasma.        -   3.2.7. Remove the remaining plasma supernatant from each            bucket containing packed red blood cells and a thin layer of            plasma using a 10 mL pipette as described in section 4.2.4            above.        -   3.2.8. A thin buff-colored layer of white cells (known as            the “buffy coat”) remains at the top of the packed red cell            layer. Remove this layer by aspirating it into a 3 mL            plastic Pasteur pipette while drawing the tip of the pipette            across the surface of the red cell layer.        -   3.2.9. Transfer the contents of the centrifuge buckets to a            1 L beaker and mix gently with a rubber spatula.        -   3.2.10. Remove a small aliquot of the mixed pack red cell            and measure the hematocrit, in triplicate, as described in            section 5 below.    -   3.3. Blending of processed egg white and blood plasma        -   3.3.1. Pour a volume of processed thick egg white into the 3            L-reaction vessel. This volume may be between 1000 mL and            1600 mL.        -   3.3.2. Pour a volume of porcine blood plasma into the 3            L-reaction vessel. This volume must be equal to 75% of the            volume of thick egg white.        -   3.3.3. Stir the mixture briefly (10-20 seconds) with a large            rubber spatula.        -   3.3.4. Lower the 3″ diameter flat, SS stirring disc into the            mixture. The stirring disc must be centered in the reaction            vessel and 5 inches below the surface of the mixture.        -   3.3.5. Turn on the stirrer, adjust the stirrer speed to 1000            rpm, and stir the mixture for 1 hour.        -   3.3.6. Stop the stirrer and remove the stirring rod and            disc.        -   3.3.7. Using a rubber spatula, remove any foam that may have            formed on the surface of the mixture during stirring.        -   3.3.8. Transfer the blended mixture to a 3-4 L beaker.    -   3.4. Addition and mixing of packed red cell        -   3.4.1. Measure the hematocrit of the packed red cells using            the procedure described in section 5 below.        -   3.4.2. Calculate the amount of packed red cells to be added            to the egg white/plasma mixture using one of the following            equations.            -   3.4.2.1. If the packed cells are to be added by volume,                use the following equation to calculate that volume:

${pRBCvolume} = \frac{0.3 \times \left( {{eggwhite}/{plasma}} \right){volume}}{{{Hematocrit}\mspace{14mu}({pRBC})} - 0.3}$

-   -   -   -   3.4.2.2. If the packed cells are to be added by weight,                use the following equation to calculate that weight:

${pRBCgrams} = \frac{0.321 \times \left( {{eggwhite}/{plasma}} \right){grams}}{{{Hematocrit}\mspace{14mu}({pRBC})} - 0.3}$

-   -   -   3.4.3. Add the calculated amount of packed red blood cells            to the egg white/plasma mixture and stir with a rubber            spatula for 1 minute.

    -   3.5. Filling of Fenwal storage bags.        -   3.5.1. Cut the access tubing on the Fenwal storage bags to a            length of approximately 24 inches.        -   3.5.2. Attach the cut end of the storage bag tubing to the            outflow of a large plastic beaker.        -   3.5.3. Pour the required fluid volume into the funnel and            allow the fluid to fill the bag by gravity flow.        -   3.5.4. Using a large syringe, remove all air bubbles from            the bag.        -   3.5.5. Measure the hematocrit of the contents of the bag            using the procedure described in section 5 below.        -   3.5.6. Seal the bag by tying a double knot in the tubing            about 2 to 3 inches from the bag, or use Fenwal metal tubing            clips, and cut off the excess tubing.            4. Hematocrit testing:

    -   4.1. Insure that the blood or simulant to be tested is at room        temperature and well mixed.

    -   4.2. Place a small aliquot (0.1 to 0.2 mL) of the fluid to be        tested in a small cup or on a piece of Parafilm.

    -   4.3. Draw the fluid up into a Hematocrit tube, leaving about 15        mm of air at the top of the tube.

    -   4.4. Hold your finger on the top of the Hematocrit tube (to        prevent the flow of fluid out of the tube) and seal the tube by        placing the bottom of the tube in the Hemoseal stand.

    -   4.5. Place the filled, sealed tubes in the Hematocrit Centrifuge        with the sealed end facing away from the center of the        centrifuge.

    -   4.6. Centrifuge the tubes for 3 minutes.

    -   4.7. Read the hematocrit of each tube using the built-in        hematocrit reader.        Intake/Rewet Test Method

The prepared absorbent composites are laid flat on the testing surface.The top of the absorbent composite is then insulted with a first 2 mLgush of room temperature menses simulant (24 mL/min), followed by a 2minute, 55 second pause, followed by a 3 mL trickle (0.3 mL/min), andthen a second 2 mL gush (24 mL/min). The menses simulant is administeredthrough a cannula 404 in a rate block 400 that is placed at the centercrotch of the test product. The rate block 400 is made of anon-electrostatic material called Ertalyte. This material allowssimulant to pass along its surface without attracting it. The opening402 is oval shaped and measures 60 mm long (L3)×13 mm wide (W3) with itsends 404 consisting of 4-mm diameter half circles. As shown in FIG. 46and FIG. 46A, the cannula 404 is inserted through a small center hole406 offset in the top of the rate block 400 to allow the cannula 404 tobe at an angle with respect to the oval opening 402 and to allow thefluid to be applied through the center of the rate block 400 ovalopening 402.

The first and second Intake values are measured with a stopwatch duringthe first and second 2 mL gush, respectively. The stopwatch is startedwhen the gush starts and is stopped when the fluid from the gush iscompletely absorbed by the absorbent composite. Rewet values aredetermined after complete penetration of the second 2 mL gush. Themeasure rewet values, two pieces of blotting paper (Verigood grade,white, 300 g/m², 48.26 by 60.96 cm stock, 250 sheets per ream,Georgia-Pacific Corp. part number 411-01-12, or equivalent) are placedto cover the insulted absorbent composite. A foot that covers theabsorbent composite is lowered against the blotter paper to create apressure load of 1.0 psi for 3 minutes and the amount of fluidtransferred to the blotting paper is determined gravimetrically. Thepressure used in this test has been shown to correlate well with thepressure applied to feminine hygiene pads during use.

In the interests of brevity and conciseness, any ranges of values setforth in this disclosure contemplate all values within the range and areto be construed as support for claims reciting any sub-ranges havingendpoints which are whole number values within the specified range inquestion. By way of hypothetical example, a disclosure of a range offrom 1 to 5 shall be considered to support claims to any of thefollowing ranges: 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2 to 5; 2 to 4; 2 to3; 3 to 5; 3 to 4; and 4 to 5.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by references, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An absorbent article comprising: a. afluid-entangled body facing material comprising: i. a support layercomprising a plurality of fibers and opposed first and second surfaces;ii. a projection layer comprising a plurality of fibers and opposedinner and outer surfaces, the second surface of the support layer incontact with the inner surface of the projection layer, fibers of atleast one of the support layer and the projection layer beingfluid-entangled with fibers of the other of the support layer and theprojection layer; iii. a plurality of hollow projections formed from afirst plurality of the plurality of fibers in the projection layer, theplurality of projections extending from the outer surface of theprojection layer in a direction away from the support layer; and iv. aland area, wherein the plurality of hollow projections are surrounded bythe land area; b. an outer cover; c. an absorbent body positionedbetween the fluid-entangled body facing material and the outer cover; d.an acquisition layer positioned between the fluid-entangled body facingmaterial and the absorbent body; and e. a fluid transfer layerpositioned between the acquisition layer and the absorbent body, thefluid transfer layer comprising a polymeric material; wherein the areaof spread of fecal material on the fluid-entangled body facing materialafter insult with fecal material simulant according to the Determinationof Area of Spread of Fecal Material Simulant Test Method is less thanabout 34 cm².
 2. The absorbent article of claim 1 wherein theacquisition layer comprises fibers having a denier of greater than about5.
 3. The absorbent article of claim 1 wherein the land area has greaterthan about 1% open area within a chosen area of the fluid-entangled bodyfacing material.
 4. The absorbent article of claim 3 wherein the landarea has greater than about 5% open area within a chosen area of thefluid-entangled body facing material.
 5. The absorbent article of claim4 wherein the land area has greater than about 10% open area within achosen area of the fluid-entangled body facing material.
 6. Theabsorbent article of claim 3 wherein the open area is due tointerstitial fiber-to-fiber spacing.
 7. The absorbent article of claim 1wherein a second plurality of fibers of the plurality of fibers in theprojection layer are entangled with the support layer.
 8. The absorbentarticle of claim 1 wherein the absorbent body is free of superabsorbentmaterial.
 9. The absorbent article of claim 1 wherein the absorbent bodycomprises greater than about 15% superabsorbent material by weight ofthe absorbent body.
 10. The absorbent article of claim 1 wherein thefluid-entangled body facing material comprises less than about 10%extension in a machine direction under a load of 2 Newtons per 25 mmwidth.
 11. The absorbent article of claim 10 wherein the fluid-entangledbody facing material comprises less than about 10% extension in themachine direction under a load of 4 Newtons per 25 mm width.
 12. Theabsorbent article of claim 11 wherein the fluid-entangled body facingmaterial comprises less than about 10% extension in the machinedirection under a load of 6 Newtons per 25 mm width.
 13. The absorbentarticle of claim 1 wherein the projections have a height from about 1 mmto about 10 mm.
 14. The absorbent article of claim 1 wherein thefluid-entangled body facing material comprises a resiliency of greaterthan about 70% according to the Percent Resiliency—One Cycle CompressionTest Method.
 15. The absorbent article of claim 1 wherein the area ofspread of fecal material on the fluid-entangled body facing materialafter insult with fecal material simulant according to the test methoddescribed herein is less than about 33 cm².
 16. The absorbent article ofclaim 15 wherein the area of spread of fecal material on thefluid-entangled body facing material after insult with fecal materialsimulant according to the Determination of Area of Spread of FecalMaterial Simulant Test Method is less than about 32 cm².
 17. Theabsorbent article of claim 16 wherein the area of spread of fecalmaterial on the fluid-entangled body facing material after insult withfecal material simulant according to the Determination of Area of Spreadof Fecal Material Simulant Test Method is less than about 31 cm². 18.The absorbent article of claim 1 wherein the projections have less thanabout 1% open area within a chosen area of the fluid-entangled bodyfacing material.
 19. The absorbent article of claim 18 wherein the openarea is due to interstitial fiber-to-fiber spacing.
 20. The absorbentarticle of claim 1 wherein the absorbent article is a diaper.
 21. Anabsorbent article comprising: a. a fluid-entangled body facing materialcomprising: i. a support layer comprising a plurality of fibers andopposed first and second surfaces; ii. a projection layer comprising aplurality of fibers and opposed inner and outer surfaces, the secondsurface of the support layer in contact with the inner surface of theprojection layer, fibers of at least one of the support layer and theprojection layer being fluid-entangled with fibers of the other of thesupport layer and the projection layer; iii. a plurality of hollowprojections formed from a first plurality of the plurality of fibers inthe projection layer, the hollow projections extending from the outersurface of the projection layer in a direction away from the supportlayer; iv. a land area, wherein the plurality of hollow projections aresurrounded by the land area; and v. the projections having less thanabout 1% open area and the land area having greater than about 5% openarea within a chosen area of the fluid-entangled body facing material;b. an outer cover; c. an absorbent body positioned between thefluid-entangled body facing material and the outer cover; d. anacquisition layer positioned between the fluid-entangled body facingmaterial and the absorbent body; and e. a fluid transfer layerpositioned between the acquisition layer and the absorbent body, thefluid transfer layer comprising a cellulosic material; wherein the areaof spread of fecal material on the fluid-entangled body facing materialafter insult with fecal material simulant according to the Determinationof Area of Spread of Fecal Material Simulant Test Method is less thanabout 34 cm².
 22. The absorbent article of claim 21 wherein a secondplurality of fibers of the plurality of fibers in the projection layerare entangled with the support layer.
 23. The absorbent article of claim21 wherein the acquisition layer comprises fibers having a denier ofgreater than about
 5. 24. The absorbent article of claim 21 wherein theacquisition layer comprises fibers having a denier of less than about 5.25. The absorbent article of claim 21 wherein the absorbent body is freeof superabsorbent material.
 26. The absorbent article of claim 21wherein the absorbent body comprises greater than about 15%superabsorbent material by weight of the absorbent body.
 27. Theabsorbent article of claim 21 wherein the fluid-entangled body facingmaterial comprises less than about 10% extension in a machine directionunder a load of 2 Newtons per 25 mm width.
 28. The absorbent article ofclaim 27 wherein the fluid-entangled body facing material comprises lessthan about 10% extension in the machine direction under a load of 4Newtons per 25 mm width.
 29. The absorbent article of claim 28 whereinthe fluid-entangled body facing material comprises less than about 10%extension in the machine direction under a load of 6 Newtons per 25 mmwidth.
 30. The absorbent article of claim 21 wherein the projectionshave a height from about 1 mm to about 10 mm.
 31. The absorbent articleof claim 21 wherein the fluid-entangled body facing material comprises aresiliency of greater than about 70% according to the PercentResiliency—One Cycle Compression Test Method.
 32. The absorbent articleof claim 21 wherein the area of spread of fecal material on thefluid-entangled body facing material after insult with fecal materialsimulant according to the Determination of Area of Spread of FecalMaterial Simulant Test Method is less than about 33 cm².
 33. Theabsorbent article of claim 32 wherein the area of spread of fecalmaterial on the fluid-entangled body facing material after insult withfecal material simulant according to the Determination of Area of Spreadof Fecal Material Simulant Test Method is less than about 32 cm². 34.The absorbent article of claim 33 wherein the area of spread of fecalmaterial on the fluid-entangled body facing material after insult withfecal material simulant according to the Determination of Area of Spreadof Fecal Material Simulant Test Method is less than about 31 cm². 35.The absorbent article of claim 21 wherein the open area in theprojections is due to interstitial fiber-to-fiber spacing.
 36. Theabsorbent article of claim 21 wherein the open area in the land area isdue to interstitial fiber-to-fiber spacing.
 37. The absorbent article ofclaim 21 wherein the absorbent article is a diaper.
 38. An absorbentarticle comprising: a. a fluid-entangled body facing materialcomprising: i. a support layer comprising a plurality of fibers andopposed first and second surfaces; ii. a projection layer comprising aplurality of fibers and opposed inner and outer surfaces, the secondsurface of the support layer in contact with the inner surface of theprojection layer, fibers of at least one of the support layer and theprojection layer being fluid-entangled with fibers of the other of thesupport layer and the projection layer; iii. a plurality of hollowprojections formed from a first plurality of the plurality of fibers inthe projection layer, the hollow projections extending from the outersurface of the projection layer in a direction away from the supportlayer; and iv. a land area, wherein the plurality of hollow projectionsare surrounded by the land area; b. an outer cover; c. an absorbent bodypositioned between the fluid-entangled body facing material and theouter cover; d. an acquisition layer positioned between thefluid-entangled body facing material and the absorbent body; and e. afluid transfer layer positioned between the acquisition layer and theabsorbent body, the fluid transfer layer comprising a cellulosicmaterial; wherein the area of spread of fecal material on thefluid-entangled body facing material after insult with fecal materialsimulant according to the Determination of Area of Spread of FecalMaterial Simulant Test Method is less than about 34 cm².
 39. Theabsorbent article of claim 38 wherein a second plurality of fibers ofthe plurality of fibers in the projection layer are entangled with thesupport layer.
 40. The absorbent article of claim 38 wherein theacquisition layer comprises fibers having a denier of greater than about5.
 41. The absorbent article of claim 38 wherein the acquisition layercomprises fibers having a denier of less than about
 5. 42. The absorbentarticle of claim 38 wherein the absorbent body is free of superabsorbentmaterial.
 43. The absorbent article of claim 38 wherein the absorbentbody comprises greater than about 15% superabsorbent material by weightof the absorbent body.
 44. The absorbent article of claim 38 wherein thefluid-entangled body facing material comprises less than about 10%extension in a machine direction under a load of 2 Newtons per 25 mmwidth.
 45. The absorbent article of claim 44 wherein the fluid-entangledbody facing material comprises less than about 10% extension in themachine direction under a load of 4 Newtons per 25 mm width.
 46. Theabsorbent article of claim 45 wherein the fluid-entangled body facingmaterial comprises less than about 10% extension in the machinedirection under a load of 6 Newtons per 25 mm width.
 47. The absorbentarticle of claim 38 wherein the projections have a height from about 1mm to about 10 mm.
 48. The absorbent article of claim 38 wherein thefluid-entangled body facing material comprises a resiliency of greaterthan about 70% according to the Percent Resiliency—One Cycle CompressionTest Method.
 49. The absorbent article of claim 38 wherein the area ofspread of fecal material simulant on the fluid-entangled body facingmaterial after insult with fecal material simulant according to theDetermination of Area of Spread of Fecal Material Simulant Test Methodis less than about 33 cm².
 50. The absorbent article of claim 49 whereinthe total area of spread of fecal material simulant on thefluid-entangled body facing material after insult with fecal materialsimulant according to the Determination of Area of Spread of FecalMaterial Simulant Test Method is less than about 32 cm².
 51. Theabsorbent article of claim 50 wherein the total area of spread of fecalmaterial simulant on the fluid-entangled body facing material afterinsult with fecal material simulant according to the Determination ofArea of Spread of Fecal Material Simulant Test Method is less than about31 cm².
 52. The absorbent article of claim 38 wherein the projectionshave less than about 1% open area within a chosen area of thefluid-entangled body facing material.
 53. The absorbent article of claim52 wherein the open area is due to interstitial fiber-to-fiber spacing.54. The absorbent article of claim 38 wherein the absorbent article is adiaper.